MC5000. Operating and Calibration Instructions

Transcription

1 MC5000 Operating and Calibration Instructions

2 TABLE OF CONTENTS 1 - CERTIFICATE OF CONFORMITY DESCRIPTION GENERAL CHARACTERISTICS WORKING PRINCIPLE Hydraulic system Electrical system Crimp head INSTRUCTIONS FOR USE SAFETY UNPACKING - INSTALLATION OPERATING INSTRUCTIONS ADJUSTMENT DIE POSITIONING FAST TOOLING OPTION FOR DIE CHANGING MAINTENANCE MAINTENANCE Die lubrication Checking and replacing the oil Cleaning the swaging head SPARE PARTS Spare machine parts Spare tools TROUBLESHOOTING WARRANTY LIMITATIONS E2/MC5000

3 1 - CERTIFICATE OF CONFORMITY EC DECLARATION OF CONFORMITY The manufacturer, the undersigned : GATES hereby declares that the new equipment described below: MC serial number: complies with the machinery directive and the specifications given by GATES and with the regulations regarding health and safety at work, as applicable. Drawn up: signature: G. R. Keast date: Machine started on: by: place: 3

4 2 - DESCRIPTION GENERAL: You have just acquired a GATES MC5000 powered crimper. It is necessary you adhere to the enclosed instructions for best performance. The MC5000 has been designed specifically for crimping the complete range of Gates hoses and couplings which are used constantly in today's industry, agriculture and public works. This user guide contains all information concerning the operation, use and maintenance of your MC CHARACTERISTICS: Crimping power: 360 tonnes (maximum measured). Pressure: 335 bar. Motor: 5,5 kw, 12 A at 380 V 3-phase. 5,5 kw, 35 A at 220 V 1-phase. Dimensions: H 690 x W 465 x L 790 mm. Weight: 260 kg with oil. Capacity: all hose types, from 3/16" to 2". Noise levels: 71 db. Oil tank: 30 litres. Pump: gear type. Die travel: 14 mm working travel and 38 mm maximum travel. Adjustment: by micrometer screw with numerical display and electrical stop. Crimping: by pressing push-button or operating foot switch. Crimping stop: automatic according to adjustment. Retraction: by pressing push-button or operating foot switch. Retraction stop: by releasing push-button or operating foot switch. Cycle time: 10 seconds for 3-phase 380 V crimper. 16 seconds for 1-phase 220 V crimper. Tooling: changing tool for intermediate dies, die-carriers and dies. intermediate retaining dies and die-carriers. GATES die sets. These specifications are nominal and must not be used for inspection. Options: - Machine base with drawers for storing dies (ref. MC SPEV50) - Machine base with shelves (ref. MC SPEP50) - Machine base with storing space for fast tooling (ref. MC SPESR) - Fast tooling for die changing, per die set (ref. MC SRxx xx being the reference of dies). 4

5 2.3 - WORKING PRINCIPLE: This machine is comprised of 3 main systems: the hydraulic circuit, the crimping head with numerical set stop for crimp adjustment, and the electrical system HYDRAULIC SYSTEM: This supplies the energy necessary to move the dies. Composition: The hydraulic circuit is comprised of (see figures 1 and 2) - a drilled block (1) - a pressure limiter (2) - a pilot valve (3) - a control valve (4) - a motor (5) - a pump (6) - a suction filter (7) - an oil tank (8) BAR Figure 1 : Hydraulic circuit diagram. 5

6 Working principle: In the non-actuated state (such as shown in figure 1), the motor drives the pump which continuously supplies the circuit with oil. The control valve (4) is in position middle (see figure 1). The oil is in a closed circuit and returns to the oil tank (8). During crimping, the control valve (4) is in position right. The connection P to B on the control valve (4) is established. The crimping chamber is supplied with oil. When pressure is equal or superior to required pressure, excess oil is returned to the oil tank (8) via the pressure limiter (2). Oil in the retraction chamber is evacuated to the oil tank (8) via the control valve (4) from A to T. During die retraction, the control valve (4) is in position left. The connection P to A on the control valve is established. The die retraction chamber is supplied with oil. A system in the bell housing allows to reduce the pressure during the return. Oil in the crimping chamber is returned to the oil tank (8) via the connection B to T on the control valve (4). The volume of oil in the crimping chamber being larger, oil is also evacuated via the pilot valve (3). Figure 2 : View of drilled block. 6

7 ELECTRICAL SYSTEM: The electrical system supplies the motor and control valve. Note: Spare fuses are attached to the switch cable in the electrical enclosure of the machine. Composition: The electrical system is comprised of (see figure 3): For supply section: - an electric motor (1) - a thermal breaker (2) - a general disconnecting switch (3) - a motor contactor (14) For control section: - 2 fuses 0,5 A am (4) and 6 A gi (5) - a micro-switch (6) - two push-buttons (7) and (8) - two control valve coils (9) and (10) - two indicator lamps (11) and (15) - a transformer (12) /24 V - a contactor (13) - 1 motor contactor (14) - 1 emergency stop (16) Figure 3 : Electrical circuit diagram. 7

8 CRIMP HEAD: This is the most technical part of the machine. Through the use of die sets, it compresses the ferrule in order to crimp it onto the hose. Composition: The crimp head is comprised of (see figure 4): - a numerical set stop consisting of: - an adjustment knob with counter (1) - a micrometer (2) - a micro-contact (3) - a contact rod (4) - a protecting cap (13) - a face flange (5) - die-carriers (6) - a set of intermediate dies (7) - a bell housing corresponding to a hydraulic ram body (8) - die-sets (9) - a hollow piston which moves under oil pressure (10) - a piston flange (11) - an oil trap ring (12) Figure 4 : Diagram of swaging head and numerical crimp adjuster. 8

9 Working principle: The bell housing (8) and piston (10) can be compared to a double acting hydraulic ram. Crimping consists in transforming a linear displacement at constant speed, that of the piston (10), into a two speed radial displacement: resulting in a rapid approach speed and a slower crimping speed. These two speeds are obtained via two slopes on the piston (10) and the die-carriers (6). The gentle slope ensures, for equal thrust on the piston (10), a slower displacement and higher crimping power. The main elements of the crimper, made from special steel, have been subjected to a series of penetrative and surface thermal treatments in order to ensure that they will stand important stresses, and to reduce wear through contact or friction. Guidance in movement is ensured via two composite rings (made from bronze-charged teflon). Sealing is obtained through 3 composite joints (made from PTFE). Also, in the unlikely event of any leaks, an oil trap ring (12) at the rear of the bell housing directs oil back to the tank. A similar device is incorporated into the face flange (5). The numerical crimp adjuster, mechanically activated by the hollow piston (10), electrically stops the crimping operation. For that purpose, it is equipped with a microswitch (3) which pilots the control valve. Adjustment of the crimp diameter is via a micrometer (2). Rotation of the micrometer changes the contact rod position (4), thereby allowing for precise adjustment of the final crimp diameter. 9

10 3 - INSTRUCTIONS FOR USE SAFETY: The machine must be mounted on a bench or on a stable base. Do not put your hand in the swaging head during operation. Do not modify technical characteristics of the machine (pressure or others). When performing any kind of maintenance upon the electrical system, ensure that the machine is disconnected from the power supply. Do not cover the electric motor ventilator. Disconnect the machine from electrical supply when working on the dies, die-carriers or intermediate dies UNPACKING - INSTALLATION: Unpack the machine without destroying the packing. From then on, the machine should only be transported in its original packing. Please retain for future use. Remove the lid from the box. Remove the screws at the bottom of the uprights; lift the uprights from the box. Put webbings under the machine, or raise it with a lift truck. Never lift the machine by the working head or any of its component parts. For best use and less fatigue for the operator, it is advisable to secure the machine horizontally on a base approximatively.75 metres in height. (Bases are available from GATES on request, reference MC5000-SPEP50, MC5000-SPEV50 or MC5000-SPER50 with or without drawers). Once you have positioned the machine, remove the blanks from the oil tank filling cap. Wait for 20 minutes, and check the oil level using the dip stick attached to filling cap. Electrically connect the motor making sure it rotates in the direction indicated by the arrow located on the casing. Check this rotation by quickly switching the main switch on and using the emergency stop. Important: faulty motor rotation can damage the pump. To change the direction of motor rotation, reverse the two phase wires to the mains plug. The machine has been preconnected to run on a 380 V 3-phase mains supply. To connect to a 220 V 3-phase or 1-phase mains supply, please consult us. Install the gauge setting mechanism on the crimp head face flange. Do this with the machine disconnected from the mains supply. For correct installation, display 000 on the counter dial by turning the counter knob counterclockwise. Attach the crimp adjuster using the two screws with springs supplied, taking care to correctly position the counter dial. 10

11 MC Disengage Engage 1. Intermediate die release mechanism hole 2. Crimper flange face 3. Gauge setting mechanism 4. Finished crimp indicator light 5. Engage die button 6. Disengage die button 7. On button 8. Emergency stop button 9. Mains on/off switch 10. Foot switch 11. Intermediate die changing tool Fig 4.a: MC5000: Identification diagram. 11

12 Connect the electrically operated crimp adjuster plug to the socket behind the front panel. Install the intermediate dies by the following operations: Ref - fig 4.a - Turn the main switch (9) to position 1 and press the ON button (7). - Press the disengage die button (6) in order to fully open the die-carriers. - Press the emergency stop button (8). - Introduce the intermediate die changing tool (11) into one of the intermediate die mechanism holes (1) on the flange face (see figure 5); push the tool in as far as possible and position the intermediate die retaining pin on back of die, into the hole in die carrier. Figure 5: Intermediate die changing. Unpacking and/or installation which do not conform to these procedures will render the warranty void OPERATING INSTRUCTIONS: Ref - fig 4.a - Turn the main switch (9) to position 1 and press the ON button (7). - Press the disengage die button (6) in order to fully open the die carriers/intermediate dies. - Press the emergency stop button (8). - Install the die set corresponding to the coupling to be crimped (see crimp information provided). - Unlock the emergency stop button and press the ON button (7). - Set the gauge setting mechanism (3) to the correct setting as indicated in the crimp information for the particular hose and connector being crimped. - Position the hose and the connector between the dies in the crimp head. - Place the ferrule in the position as specified in the crimp information. - Press the engage die button (5) or the foot switch (10) engage pedal to carry out the crimping operation until the finished crimp indicator light (4) lights up. - Press the disengage die button (6) or the foot switch (10) disengage pedal to release the crimped assembly. - Check the crimp diameter of the ferrule with a vernier or micrometer*. The measured crimp diameter must be within the tolerance published in the crimp information. If not, the hose assembly cannot be used and adjustment will be required. Correct the gauge setting if required. In order to decrease the crimp diameter, reduce the value on the gauge setting mechanism (3); reverse procedure to increase crimp diameter. A rotation of 7 units on the gauge setting mechanism is equal to a change of 0.10 mm on the crimp diameter. Gauge settings must be considered a guide to achieving the correct crimp diameter. Actual crimp diameters must be within the specified crimp tolerance. *Always use verniers or micrometers that are graduated to 0.001"/0.02 mm or smaller. 12

13 3.4 - ADJUSTMENT: Before delivery, each machine is calibrated and should be ready for use upon receipt. However, machine calibration should be checked on a monthly basis and when gauge settings consistently produce diameters away from that required in the crimp specification. Calibration procedure is as follows: To calibrate using calibration shell D11158 (Megacrimp shell ) or any ES08 (08G) coupling. - Place die set N 20 (N 33) in the machine. - Set the gauge setting mechanism to 420 (200). - Crimp the calibration shell D11158 ( ). - Measure the crimped diameter of the calibration shell it should read 25.4 (26.0) +/- 0.1 mm. - If the crimp diameter is as specified, the machine is correctly calibrated. - If the crimp diameter is outside the stated dimensions, it is necessary to recalibrate the machine as follows: 1. Isolate the machine from power supply. 2. Note by how much the measured crimp diameter differs from the required 25.4 mm calibration diameter. 3. Unscrew the two socket head screws that hold the gauge setting mechanism in place with a 3 mm Allen Key, and remove the unit. 4. Calibration adjustment is now via the 6 mm screw and locknut. One full turn of the screw clockwise (when viewed from the screw end) will reduce the crimp diameter by 0.4 mm. Turning the screw anti-clockwise increases the crimp diameter 0.4 mm. 5. Unlock the locknut and turn the screw the required amount according to the difference between the achieved and the required crimp diameter. 6. Lock the locknut and replace the gauge setting mechanism, tightening the two socket head screws. 7. Crimp a new calibration shell D11158 (use the same type as before - ES08 or 08G-) and check that the correct crimp diameter has now been achieved. 8. If the required crimp diameter is not achieved, repeat the recalibration process DIE POSITIONING: Dies can be positioned in four ways to enable effective crimping of Gates couplings (as seen in figures 6, 7, 8 and 9). Figure 6 : location 1. Figure 7 : location 2. For straight couplings For all 90 and 45 couplings Coupling Coupling intermediate die die die number stamped here die number stamped here (for ES, HS and HA only) die intermediate die die-carrier crimper front of machine die-carrier crimper front of machine Figure 8 : location 3. For straight couplings For all dies, except die types 60A, 60C and 65. Figure 9 : location 4. For all 90 and 45 couplings Coupling Coupling die die number stamped here die number stamped here die die-carrier crimper front of machine die-carrier crimper front of machine For die types 60A, 60C and 65 only. Note: When dies are in location 2 and 4 with dies reversed, it is advisible to operate the machine from the side. This enables clear view into the back of the head to enable correct coupling location according to the Gates crimp data. 13

14 3.6 - FAST TOOLING OPTION FOR DIE CHANGING: The fast tooling option enables die positioning and removal as follows (valid for all die sets). Gauge setting for all changing operations is 110 DIE POSITIONING 1. close crimper at 110 gauge setting 2. insert tool with dies firmly at centre of crimper DIE REMOVAL 1. open crimper 2. insert tool, with handle at 90 angle, by placing it on bottom die-carriers to avoid jamming when crimper closes bend handle 90 to unlock 3. close crimper at 110 gauge setting 4. straighten handle open crimper 5. remove empty tool 5. pull back tool with dies by pulling back the handle Each rapid tool corresponds to a specific die set. Check marks before each use. 14

15 4 - MAINTENANCE MAINTENANCE: DIE LUBRICATION: Friction on the dies whilst crimping is very important. For this reason, it is necessary to lubricate the bearing surface of the die-carriers on the piston regularly. Indeed, an insufficiently lubricated machine could seize, or the pistons and die-carriers could be subjected to increased wear. To achieve correct lubrication, grease with a 60% concentration of molybdenum di-sulphide (this product is supplied with the machine and can be obtained from GATES). Lubricate every 100 crimping operations as follows: - Shake the aerosol can, held upside down, for 1 minute (time necessary for such a thick product to be vaporised properly). - Remove the intermediate dies if necessary. - Advance the die-carriers on the rapid cone. The die-carriers should be 5 mm above the face flange (see figure 10). Figure 10 : Position of die-carriers for lubrication. - Introduce the aerosol can diffuser in the hole located at the rear of the die-carriers (lubrication point N 1 - see figure 11). Figure 11 : Lubrication point N 1. Recommended grease: see above. - Grease the piston through the holes of each die-carrier. 15

16 - From the rear of the bell housing, diffuse the grease all around the cone (lubrication point N 2 - see figure 12). Figure 12 : Lubrication point N 2. Recommended grease: see above. - Completely close the die-carriers. - From front of machine, lubricate between the die-carriers and the face flange (lubrication point N 3 - see figure 13). Figure 13 : Lubrication point N 3. Recommended grease: see above CHECKING AND REPLACING THE OIL: - Regularly check the oil level about every 500 swagings. - Empty the oil tank each year and replace the used oil with new oil (the machine is delivered with a full tank of hydraulic oil type ISO HV 32) CLEANING THE SWAGING HEAD: - Regularly dismantle the face flange and the die-carriers about every three months. This is necessary to ensure that metallic/other particles are removed before causing damage to machine parts. Dismantle as follows: - Put die set N 35 into location 1 with dies reversed so that they protrude past the face flange. - Remove gauge setting mechanism - the crimper must be fully opened. - Remove the 12 cap head screws from the face flange. - Carefully remove the flange with the 8 die-carriers. - Clean and lubricate all surfaces using recommended grease. - Remount the flange and the die-carriers. Ensure that it is correctly located for the gauge setting mechanism. - Tighten the 12 screws with a torque wrench at 28 MKg. (tightening in star with spreading of the effort) This operation can be difficult for an inexperienced mechanic. When in doubt, don't hesitate to contact your Gates representative. 16

17 4.2 - SPARE PARTS: Note: Tampering with the machine during the warranty period will render the latter void. All orders for spare parts must state reference, computer code and quantity required. Example: Reference: PISTON Computer code: MC Quantity: SPARE MACHINE PARTS (see figure 14): Position REF Description P/N Quantity - pos. 9 / fig. 14 MC Piston flange MC Position switch MC Body's switch of push button pos. 2 / fig. 3 MC Thermical circuit breaker pos. 6 / fig. 14 MC Composite seal ø 260 mm MC Signal's body MC Die changing tool pos. 1 / fig. 4 MC Revolution counter button pos. 3 / fig. 14 MC Piston pos. 13 / fig. 14 MC Head pos. 1 / fig. 3 MC Motor 5,5Kw 380V 3Ph pos. 16 / fig. 14 MC CHC M16* screw MC Bulb pos. 5 / fig. 14 MC Piston ring pos. 7 / fig. 14 MC Piston flange ring pos. 14 / fig. 14 MC Composite seal ø 330 mm pos. 8 / fig. 14 MC Composite seal ø 250 mm pos. 18 / fig. 14 MC Tightening ring pos. 11 / fig. 14 MC Gauge pos. 15 / fig. 14 MC Head flange MC Pilot valve pos. 25 / fig. 14 MC Intermediate dies pos. 10 / fig. 14 MC Oil trap ring pos. 12 / fig. 3 MC Electrical transformer pos. 21 / fig. 14 MC Pin pos. 6 / fig. 1 MC Gear pump pos. 4 / fig. 1 MC Control valve pos. 1 / fig. 14 MC Master dies pos. 2 / fig. 14 MC Spring master dies pos. 17 / fig. 14 MC Die nipple Page 4 MC Pressure limiter (from machine 0498) 1 pos. 13 / fig. 4 MC Protection gauge pos. 3 / fig. 3 MC Main contactor 1 pos. 13 / fig. 3 MC ON (lit) push button pos. 7,8 / fig. 3 MC Green push button pos. 16 / fig. 3 MC Emergency stop pos.11,15 / fig.3 MC Yellow signal pos. 23 / fig. 14 MC Blocking axis pos. 24 / fig. 14 MC Blocking spring MC Rubber bellows pos. 3 / fig. 1 MC Pilot valve (from machine 0497)

18 Position REF Description P/N Quantity pos. 4 / fig. 14 MC O-ring R N Page 4 MC HP discharge valve (before machin 0498) Page 4 MC BP discharge valve pos. 14 / fig. 3 MC Contactor pos. 6 / fig. 3 MC Microswitch pos. 5 / fig. 3 MC Fuse 6 A gi pos. 4 / fig. 3 MC Fuse 0,5 A am pos. 22 / fig. 14 MC Die retaining pin S8X MC Rubber bellows locking pin MC Body switch of emergency stop pos. 20 / fig. 14 MC Ring ø 8 mm SCHNOR pos. 19 / fig. 14 MC CHC M8* screw MC5000-HEAD Standard exchange crimping head MC5000-COVER Electrical casing MC5000-GREASE Grease in aerosol can SPARE TOOLS (see figure 14): Position REF Description P/N Quantity MC5000-D10 Standard dies MC5000-D15 Standard dies MC5000-D20 Standard dies MC5000-D30A Standard dies MC5000-D30B Standard dies MC5000-D35 Standard dies MC5000-D37 Standard dies MC5000-D40 Standard dies MC5000-D45 Standard dies MC5000-D60A Standard dies MC5000-D60C Standard dies MC5000-D65 Standard dies MC5000-D310 Standard dies MC5000-D311 Standard dies MC5000-IH73 Dies for industrial hose MC5000-IH80 Dies for industrial hose MC5000-IH90 Dies for industrial hose MC5000-IH95 Dies for industrial hose MC5000-IH99 Dies for industrial hose MC5000-IH112 Dies for industrial hose MC5000-IH117 Dies for industrial hose MC5000-D400 Dies P1T03 & MC5000-TC350 Dies for T MC5000-TC400 Dies for T MC5000-TC600 Dies for T MC5000-TC750 Dies for T MC5000-TC900 Dies for T MC5000-TC1020 Dies for T MC5000-TC1140 Dies for T MC5000-SPEP50 Standard table MC5000-SPEV50 Table with drawers MC5000-SPESR Table for fast tooling

19 Position REF Description P/N Quantity MC5000-SR10 Fast tooling for D10 dies MC5000-SR15 Fast tooling for D15 dies MC5000-SR20 Fast tooling for D20 dies MC5000-SR30A Fast tooling for D30A dies MC5000-SR30B Fast tooling for D30B dies MC5000-SR35 Fast tooling for D35 dies MC5000-SR37 Fast tooling for D37 dies MC5000-SR40 Fast tooling for D40 dies MC5000-SR45 Fast tooling for D45 dies MC5000-SR310 Fast tooling for D310 dies MC5000-SR311 Fast tooling for D311 dies MC5000-DRAWER Additional drawer for SPEV Figure 14 : Composition of the swaging head. 19

20 4.3 - TROUBLESHOOTING: Problem Probable cause Possible solutions The press won t open or Lubrication error Clean and lubricate the press (see does not crimp sections and 4.1.3). The control valve is not piloted Check the electrical circuit: fuses, plugs and connections, feeding of the control valve bobbin, position of the safety stroke switch. Crimping power is not sufficient Wrong choice of dies Use the dies as specified by the crimping information provided with the machine. Inadequate hydraulic pressure Calibration of high pressure to 360 bars during crimping (set in factory). Unlock the discharge valves if necessary. Hydraulic leaks Check and replace malfunctioning seals. The control valve does not work Maintain or replace the control valve. Dies move out of position Dies are incorrectly mounted Replace damaged mounting pins or reposition die retaining pins. Electrical motor makes 2-phase operation Check electric supply, fuses abnormal noise and connections. 20

21 4.4 - WARRANTY LIMITATIONS: GATES machines are guaranteed against defects and faulty workmanship for a period of one year from date of purchase. During the period of warranty, GATES will repair (or replace as the case may be) free of charge all faulty parts, provided the machine is returned to the works. This warranty will not apply in the case of accidental damage, misuse or if the machine has been subjected to repairs or modifications by persons other than GATES. GATES cannot be held responsible for any damage or injury direct, indirect or consequential to the use of its machines, nor after express or implicit termination of warranty. This warranty replaces all other warranties including implicit warranties. Every effort has been made to ensure the accuracy and comprehensiveness of the informations included in this guide. However, Gates cannot be held responsible for errors or omissions and alterations which have occured after release for printing; or if Gates products are used in special or exceptional circumstances without prior consultation with and clearance from a Gates representative for verification of the planned usage. For more information, please contact: Gates Hydraulics Ltd Station Road St Neots, Huntingdon, Cambs. PE19 1QF, UK TL: (44) / FX: (44) / Gates Hydraulique S.A B.P. 14 F Meyzieu-Cedex TL: (33) FX: (33) Gates Europe N.V. Dr. Carlierlaan 30 B Erembodegem TL: (32) 053 / FX: (32) 053 / Gates GmbH Haus Gravener Str D Langenfeld TL: (49) / FX: (49) / Publishing, 09/98 The world s most trusted name in belts and hose. 21