OPERATING INSTRUCTIONS FINN-POWER
Contents
1. 5 QUICK FIX PACKAGE u ccccccccsccsssscscssesessessscssesesesesesvesssavssessasessavaresesvessseassssasasessavsseasavsssseavesesvereseseseacaeeeavevee 5 OPERATION aec 6 CONTROL IDENTIFICATION MS 2 99 9 6 CONTROL IDENTIFICATION IS AS VS CONTROLS cccccccscssscosssesesscsescssesesccssscsssssesssseatesesesresescereseavereeeavee 6 CONTROL PANEL IS AS CAS IP DEAD bated 7 SG corsi LP de MN M AQ m 9 COVERS c MENTEM TW MM 11 TEST RUN MS IS AS 5 0 9 9 4 9 9 11 11 SELECTING THE DIE SET 20 21 00 0 9 tette te 12 SELECTING THE DIE SET 22 00 teet teret te terrere rta terea tortas ta asap 12 SELECTING THE DIE SET P32 ccccccccccsccossesssccsscssscscsescsscscsessesessesssscsssesscassesscacsscasacsseassesscasssssaesasacsenescesens 13 SELECTING THE DIE SET P51 eerte kn nk uan reete tette terrere 13 FP140 DIE SETS FOR 51 00 00 9 9 2 4 9 4 14 INSTALLING THE DIE2. Dn a I aS nAn A AS AS EA a a rna 22 FILTER CHANGE 51 u c ccccccccssscscscsscscscsscscsesscscsscsesesscscsesscassscsescsscassssscassssssacssesescsucassesssacsscnsasersacssesescsscaeses 23 ae aee zae e ea E 23 FINAL DECELERATION 51 444000 nL uan ua L nn uA L ASL SA AA AAS teresa ro Ea a nna 23 RE CALIBRATION OF CRIMPING DIAMETER DIAL MS CONTROL cccccccccscsssscssssssessssessesesesescsceseseasen 23 TROUBLESHOOTING 24 222 24 jizeuhle mAb qp 25 TECHNICAL DATA 20 8 25 TECHNICAL DATA 21 22 8 9 89 3 8 27 LL 29 TECHNICAL DATA PS ROM ith HMM 30 TECHNICAL DATA CC 22 cw 32 GENERAL FINN POWER crimping machines are electrically operated hydraulic crimping machines for hydraulic hose assemblies The crimping machine comprises a crimping head and a hydraulic unit mounted on the oil tank which serves as machine frame
3. protect your hands from getting crimped don t ever touch the stop device AUTOMATIC MODE FOOT PEDAL 4 ISIAS L 8 OPTION As an alternative a foot pedal can be installed in the stop device plug e g when large fittings are crimped and more space is needed behind the machine The foot pedal enables holding the hose assembly with both hands In FOOT PEDAL mode dies will move as long as the pedal is pressed or till the set crimping diameter has been reached The crimping movement can be interrupted by lifting the foot from the pedal If need be dies can be opened by using the retraction button Adjustment of retraction diameter IS AS Turn the mode selector to O position Start the machine by pressing the start button Select manual mode Press the crimping button until the dies completely close Turn the retraction diameter control dial counterclockwise up to the minimum Select semi automatic mode Turn the retraction diameter control dial gradually clockwise While the dial is turned the dies will open Insert the uncrimped fitting between the dies as soon as the opening is large enough Release the retraction diameter control dial at that position which then becomes the final setting Ie us If the machine does not work Make sure the supply disconnecting device is in position 1 Check that the plug is in the socket MS model If the motor is running but the machine does not crimp check that
4. 1 5 230 12 6 16 Frequency 60 Hz 3 6 210 15 6 25 230 10 8 20 400 6 2 16 l Special diameters and profiles to customer s specifications Overall dimensions Weight 130 kg excluding oil M10x1 5 609 A TT E n 1 5 230 12 5 16 p Lig Ih eet VO 20mmitat eps READ THE INSTRUCTIONS THOROUGHLY SECURE SAFE AND CORRECT OPERATION OF THE MACHINE Technical data P21 Capacity Crimping diameter range Max opening Pump Max pressure Crimping force Theoretical production capacity Sound pressure level Enclosure class Closing speed of master dies Motor power Voltage V Current A Fuse A Motor power Voltage V Current Fuse in mm mm l min bar kN per hour dB A mm s kW kW 3 phase 17 4 61 34 8 275 1370 850 71 54 2 5 Frequency 50 Hz 3 200 16 25 230 11 7 20 400 6 7 16 Frequency 60 Hz 3 6 210 15 6 25 230 10 8 20 400 6 2 16 Special diameters and profiles to customer s specifications Overall dimensions 1 5 230 12 6 16 1 5 230 12 5 16 475 Weight 186 kg excluding oil P21mit hgl 2 READ THE INSTRUCTIONS THOROUGHLY SECURE SAFE AND CORRECT OPERATION OF THE MACHINE 28 Technical data P32 Capacity Crimping diameter range Max opening Pump Max pressure Crimping force Theoretical production ca
5. 5 CRIMPING BUTTON The dies will close when this button is pressed The dies move until the button is released or the set crimping diameter has been reached When using this button manual mode must be selected When the machine is started with the mode selector in manual mode crimping cannot be started using the crimping button before first selecting O position or opening dies with retraction button 7 Dies will not open if they are already in the set retraction position signal lamp 8 illuminated 6 CRIMPING DIAMETER REACHED The signal lamp is illuminated when the dies have reached the set crimping diameter 7 RETRACTION BUTTON The dies will open when this button is pressed The dies open until the button is released or the set retraction diameter has been reached When using this button manual mode must be selected 8 RETRACTION DIAMETER REACHED The signal lamp is illuminated when the dies have reached the set retraction diameter i e retraction position Automatic mode cannot get started unless the retraction position has been reached 9 DELAY SIGNAL LAMP The signal lamp is illuminated when the delay function is active 10 RETRACTION DIAMETER CONTROL The dial is used to adjust the retraction diameter of master dies after the crimping cycle Adjust the retraction large enough so that the fitting to be crimped is easy to insert between the dies but the extra movement is as short as possible The retraction becomes la
6. FINN POWER crimping machine is normally delivered with a 3 phase electric motor On request it can be equipped with a single phase motor Transport The packed machine is transported on a pallet which is easy to move and lift by a fork lift truck After unpacking the machine can be lifted using a hoisting belt Size of package for P51 models x 102 82 2 113 Size of package for other models x 77 62 z 81 cm Storage The manufacturer has protected the machine against corrosion by using the Zerust method The machined parts have been treated with Axxatec 77C protective agent A Zerust vapor capsule has been put into the electric box and the machine has been packed into a bag Pakkaus1 eps made of Zerust film The protection is effective for months if the package is not opened After opening it the protection of the wrapping film ceases If the machine is not yet brought into use it must be reprotected against corrosion The machine is to be stored in dry indoor conditions Remove the protective agent according to the instructions enclosed in the package Mounting The adjacent picture shows an appropriate way to lift the machine after it has been unpacked It is recommended to mount the machine on a Finn Power table Before mounting the table must be screwed on the floor with four M12 wedge anchors Boreholes in the floor 2 12 mm depth 55 mm When the machine is mount
7. Keep the cover open by using e g a block of wood e Unscrew the filter insert and remove it Draining plug e Handle the old filter according to law e Lubricate the seal of the new filter insert with hydraulic oil e Screw the filter insert on P20suode hgl e Filter insert must be changed together with oil Purchase number 043167 Block of wood 22 Filter change 51 Open the covering plate in the tank cover Unscrew the filter insert and remove it Handle the old filter according to law Lubricate the seal of the new filter insert with hydraulic oil Screw the filter insert on e Filter insert must be changed together with oil e Purchase number 043167 Pressure pipes Return cylinders on both sides of the crimping head produce the piston movement X backwards and simultaneous retraction of dies Hydraulic pipes to the two cylinders are high pressure pipes 275 bar To prevent leakage be careful not to damage these pipes and their connectors In case you notice leakage in a connector make sure it is properly tightened Leaking pipes must be replaced immediately DO NOT REPAIR PIPES Final deceleration P51 Filling cap Covering plate Filter Draining plug P50suod hgl To improve the crimping result model P 51 are equipped with a slow down of 1 2 mm at the end of the crimp The slow down has been set at the factory and cannot be altered by the operator The slow down is activated e
8. 20 l P50mit hgl 30 Weight 260 kg excluding oil READ THE INSTRUCTIONS THOROUGHLY TO SECURE SAFE AND CORRECT OPERATION OF THE MACHINE P50mit hgl 31 Technical data 22 Capacity Crimping diameter range Max opening Pump Max pressure Crimping force Theoretical production capacity Sound pressure level Enclosure class Closing speed of master dies Motor power Voltage V Current A Fuse Motor power Voltage V Current A Fuse A in mm mm l min bar kN per hour dB A mm s kW kW Frequency 50 Hz 3 200 16 25 230 11 7 20 400 6 7 16 Frequency 60 Hz 3 6 210 15 6 25 230 10 8 20 400 6 2 16 Special diameters and profiles to customer s specifications Overall dimensions Weight 125 kg excluding oil M10x1 5 1 5 230 12 6 16 1 5 230 12 5 16 LE gt 475 20mmitat eps 32 READ THE INSTRUCTIONS THOROUGHLY SECURE SAFE AND CORRECT OPERATION OF THE MACHINE 33
9. When the crimping diameter is being adjusted VS control automatically recommends a die set best suited for the selected diameter If desired the operator may use another die set covering the diameter question Thus he may manage to avoid changing die sets but the crimping result will not be as good as if the recommended die set would have been used 9 CORRECTION Different fittings require more or less crimping force The machine frame design however contracts and expands according to the required crimping force That is why the crimping diameter must be corrected in order to reach the intended crimping result It is recommended to use the correction function in modifying the crimping diameter so that the correct crimping diameter for the fitting in question could be saved on the crimping diameter display for the next time it is needed 10 RETRACTION DIAMETER The retraction diameter indicates the opening of master dies after the crimping cycle Adjust the retraction large enough so that the fitting to be crimped is easy to insert between the dies but the extra movement is as short as possible The retraction value is the diameter of the opening between the dies in millimetres 11 CRIMP COUNTER The counter counts crimps either from zero or from a set value onwards 12 FITTING TYPE Crimping data of your own or of the fitting manufacturer can be stored in the memory of the control unit You can name a fitting type as you like
10. 2 Motor protection tripped Reset If tripped again check motor and pump condition 3 Switch broken Check the voltage up to the motor 4 Low supply voltage Check the voltage Motor runs but no 1 Wrong rotation direction Interchange two phases in the piston movement supply disconnecting device 2 Low oil level Check refill 3 Fuses rectifier transformer out of order Check replace 4 Dial broken MS Check replace 5 Control broken IS AS VS IS AS models Check replace VS model See error code of the control unit 6 Valve out of order Check movability of valve steam Check the solenoids 7 Pump or coupling broken Check replace Insufficient crimping force 1 Insufficient lubrication Lubricate the dies 2 Low oil level Check refill 3 Pressure relief valve stuck Check clean Pilot check valve leaking Replace if broken 4 Leaking pump pressure pipe Check tighten replace 5 Coupling between motor and pump slipping Check replace Crimping diameter varies 1 Insufficient lubrication Lubricate the dies 2 Set value changed Check 3 Dial knob loose MS Check calibrate tighten 4 Dial loose IS AS Check calibrate tighten 9 Dial loose or broken MS Check tighten replace 6 Sliding potentiometer loose or broken IS AS VS Check fasten replace 7 Valve sticking Check clean In VS model see also VS control Chapter Alarm screen on page 14 GUARANTEE The machines produced by Lillbacka Powerco Oy are g
11. get between the dies Mount the die set between master dies Fig 2 and start closing the dies TO AVOID DAMAGING MASTER DIES MAKE SURE THAT ALL DIE SET PINS HIT IN THEIR HOLES Close the master dies completely until the pins are locked in their places Fig 3 Remove the tool Fig 4 Open the dies to the retraction position The dies are now ready for use Die set is removed from the press in reverse order close the dies insert the tool into the die set open the master dies and place the set back in the table CHANGE OF A SINGLE DIE P20 P21 P32 CC22 Start the motor and depress the retraction button until maximum retraction is reached Stop the motor CAUTION THE MOTOR SHALL ALWAYS BE STOPPED IM DURING INSTALLATION OF DIES i a Prior to installing dies clean the contact surfaces of both the die UN 1 set and master dies properly to avoid damaging the surfaces zi Pull the pull pin in the master die with the tool delivered together 3 2 with the machine see figure 1 lt 4 Insert the die with the retaining pin into the master die number always towards you Release the pull pin After installing all the dies make sure they are straight and properly seated in the master dies Fork20 eps CHANGE OF A SINGLE DIE P51 CAUTION THE MOTOR SHALL ALWAYS BE STOPPED DURING INSTALLATION OF DIES Start the motor and depress t
12. knob of the dial will add 1 mm to the crimping diameter Each crimping diameter chart P20 MS division on the measuring scale corresponds to 1 100 mm 47 49 50 53 54 55 56 57 EXAMPLE Manufacturer has specified crimping diameter of 20 6 mm for the fitting Select die set No 20 19 min crimping diameter 19 mm according to the die chart Turn the dial to position 1 60 upper scale 1 lower 60 This setting will give the crimping diameter 20 6 mm 19 1 6 mm The machine has been calibrated at the factory with 40 bar pressure This means that when you are crimping a fitting requiring 40 bar pressure the measuring scale of the crimping diameter dial provides an accuracy of 0 1 The crimping diameter chart P32 MS mm possible elastic recovery of the fitting not regarded When fittings requiring higher pressure are crimped the crimping diameter may become larger than the value on the scale due to machine deflections Then the crimping diameter has to be corrected by changing the scale value 16 Setting the crimping diameter IS AS From the crimping diameter chart on the electric box door you can see the die set numbers the cor responding crimping ranges The upper section of the chart shows cor responding dial position for each crimping diameter in the columns The upper dial positions are for AS and lower for IS models Crimping diameters in the grey z
13. the motor rotates in wrong direction Correct by interchanging two phase conductors in the supply disconnecting device Test run VS control e Start the motor e Adjust the crimping diameter to 10 0 and the retraction to the maximum value e During the first crimping cycles air in the cylinders may make the piston dies move irregularly and at high speed Cycle the press a few times till the motion becomes even e To avoid accidents make sure that there are no foreign objects between the dies e n case the dies do not move in either direction the motor rotates in wrong direction Correct by interchanging two phase conductors in the supply disconnecting device e Test the operation of each button and adjustment in the panel according to Chapter Control panel Read throughly through also the VS control operating instructions 11 Selecting the die set P20 P21 Use only original Finn Power die sets in Finn Power crimping machines Refer to the fitting manufacturer s specifications for proper crimping diameter for the fitting Each die set has its own crimping range Follow it to assure the roundest possible crimping result The minimum crimping diameter D is marked on each die set Example with die set No 18013 10 the minimum crimping diameter is 10 mm In addition to the standard die sets a wide range of special die sets is available on request Die set No 18013 10 18013 12 18013 14 18013 16 18013 19 18013 23 18013 27 18
14. 013 31 18013 36 18013 41 18013 47 18013 54 Crimping range 12 mm 14 mm 16 mm 19 mm 23 mm 27 mm 31 mm 36 mm 41 mm 47 mm 54 mm 61 mm 4D Qb Selecting the die set CC22 Use only original Finn Power die sets in Finn Power crimping machines 18013ins eps Refer to the fitting manufacturer s specifications for proper crimping diameter for the fitting Each die set has its own crimping range Follow it to assure the roundest possible crimping result The minimum crimping diameter D is marked on each die set Example with die set No 18315 10 the minimum crimping diameter is 10 mm Die set No 18315 10 18315 12 18315 14 18315 16 18315 19 18315 23 18315 27 18315 31 18315 36 18315 41 18315 47 Crimping range 12 mm 14 mm 16 mm 19 mm 23 mm 27 mm 31 mm 36 mm 41 mm 47 mm 54 mm Q 18013ins eps In addition to the standard die sets a wide range of special die sets is available on request 12 Selecting the die set P32 Use only original Finn Power die sets in Finn Power crimping machines Refer to the fitting manufacturer s specifications for proper crimping diameter for the fitting Each die set has its own crimping range Follow it to assure the roundest possible crimping result The minimum crimping diameter D is marked on each die set Exampl
15. 12 14 mm 14 55 18506 14 14 160 mm ooo gee 16 55 18506 16 16 19 mm 5 P 19 55 18506 19 19 22 mm O 22 70 18506 22 22 26 mm 26 70 18506 26 26 30 mm o 30 70 18506 30 30 34 mm e Qo 34 75 18506 34 34 39 mm 39 75 18506 39 39 45 mm 45 90 18506 45 45 51 mm z 51 90 18506 51 51 57 mm IM S 57 100 18506 57 57 63 mm 63 110 18506 63 63 69 18506ins eps 69 110 18506 69 69 75 mm 74 110 18506 74 74 80 mm 78 110 18506 78 78 84 mm P51 model see chapter operation limitations 13 FP140 DIE SETS FOR P51 MODEL FP140 die sets for large fittings are attached directly to the master dies FP 140 die sets are manufactured with following dimensions D L Die set No Crimping range 84 110 18860 84 84 92mm 92 110 18860 92 92 100 mm 100 110 18860 100 100 108 mm 108 110 18860 108 108 116 mm 116 110 18860 116 116 124 mm In addition to the standard die sets and FP140 die sets a wide range of special die sets are available on request Installing the die set QUICK CHANGE MSI IS AS OPTION An optional Quick Change Tool Base enables storing die sets under the machine Die sets can be installed into the master dies with a quick change tool one set at a time e Before installing dies make sure that the master dies are clean e STOP THE MOTOR PRIOR TO CLEANING DIES S AS models After that start the motor select manual mode a
16. Lillbacka Powerco Oy PO B 1 FIN 62301 Finland tel 358 6 485 4444 fax 358 6 485 4400 2 E OPERATING INSTRUCTIONS FINN POWER P20 MS P20 IS AS P20 VS P21 MS P21 IS AS P21 VS P32 MS P32 IS AS P32 VS P51 IS AS P51 VS CC22 IS AS CC22 VS EI ET ET ETE MANUFACTURING YEAR RELEASED 06 00 KEEP THIS MANUAL FOR FUTURE NEEDS THE MACHINE HAS BEEN DESIGNED FOR CRIMPING HOSE FITTINGS LILLBACKA POWERCO SHALL NOT BE HELD LIABLE FOR ANY PRODUCT WHICH HAS BEEN CRIMPED ON THE MACHINE THE MACHINE HAS BEEN DESIGNED TO OPERATE IN ROOM TEMPERATURE IN DRY INDOOR CONDITIONS AND IN SUFFICIENT ILLUMINATION USING THE MACHINE FOR ANY OTHER PURPOSE IS NOT ALLOWED WITHOUT WRITTEN CONSENT FROM THE FACTORY 5 2 GENERAL ETT 3 TRANSPORT 3 STORAGE IM IDEEN P M MNA EM UM MN EMIL 3 PUI TING S ce sete ue M E MAN RE M E 3 ases Lee 4 GENERAL 4 DANGER ZONES 4 COMMISSIONING ID e AED Ee EE 5 5 ELECTRICAL CONNECTION 000 0400
17. SET reete ertet tete terrre rte tette tette rere AE 14 QUICK CHANGE MS IS AS octies tercie n e te boire red ded 14 oun MM M UE 15 CHANGE OF A SINGLE DIE P20 P21 P32 CC22 ccccccccccssssssssessssssestssesessesesesssesresesteresesteseaveesesteeeees 15 CHANGE OF A SINGLE DIE 51 tette 15 SETTING THE CRIMPING DIAMETER MS teret tette 16 SETTING THE CRIMPING DIAMETER 18 5 000 17 SETTING THE CRIMPING DIAMETER VS terree terere SAA EA terae re rata 18 OPERATION LIMITATIONS P51 22 2 9 9 9 18 CRIMPING MS ONE O 18 CRIMPING ASIASIVS lt CONTROL Ss a loci dict Disa sette 19 ADJUSTMENT OF RETRACTION DIAMETER 185 86 4222 000 000 20 IF THE MACHINE DOES NOT 0 9 9 9 44 21 at ee ede 21 GREASING P20 21 GREASING risu 21 22 OIL CHANGES dt E i uM 22 FILTER CHANGE P20 P21 P32 22 00
18. TING HOLD THE HOSE FAR ENOUGH TO AVOID CRIMPING YOUR HAND nmm MANUAL MODE gt ees taas wmf Manual mode is used during die set change set up and test run Select MANUAL MODE Press the start button Adjust the recommended crimping diameter P51 and CC22 models Always insert the hose from the front side so that the fitting settles in the rear part of the die see figure below Press the crimping button until the dies hold the fitting lightly Adjust the retraction diameter when required Press the crimping button until the dies stop Open the dies and remove the fitting Check the crimping diameter If necessary perform fine adjustment using the correction function VS model with the crimping diameter dial IS AS models ON o Orgia 50 2 50takaa2 tif Crimping direction in 51 and CC22 models SEMI AUTOMATIC MODE Semi automatic mode is used when performing small quantities of crimps 1 Adjust the crimping and retraction diameters 2 Select SEMI AUTOMATIC MODE 3 Insert the hose assembly between the dies 4 Press the semi automatic crimping button and dies perform a crimping retraction cycle The cycle can be interrupted by releasing the button If need be dies can be opened by using the retraction button automatic Bj isas vs Automatic mode is best suited for serial production Pressing the fitting against the stop device starts the crimping
19. alled TRIP position Restart the machine by turning the handle first to O position reset and after that to l position In an emergency the supply disconnecting device is used as an emergency stop 2 CONTROL OPERATIONAL The signal lamp is illuminated when operating voltage is available and the control is ready for use 3 MODE SELECTOR The crimping head does not operate when the mode selector is in position O The mode selector should be in O position when the machine is started nmm MANUAL mas Master dies be opened by pressing retraction button 7 and closed by pressing crimping button 5 Manual mode is used when changing dies and adjusting settings Ees taas wmf SEMI AUTOMATIC E Crimping movement gets started when the semi automatic crimping button 4 is pressed The movement can be interrupted by releasing the button If need be dies can be opened by using retraction button 7 Crimping goes on when the button is repressed After reaching the crimping diameter dies return to the retraction position irrespective of whether the button is pressed or not Cycle wmf AUTOMATIC Ex Crimping movement gets started when the fitting is pressed against the stop device The movement stops if the stop device is not adequately pressed by the fitting It can also be stopped by withdrawing the fitting from the stop device before it is gripped by dies If need be dies can be opened by using retraction button 7 Crimping goes on when the f
20. e with die set No 18506 10 the minimum crimping diameter is 10 mm D L Die set No Crimping range 10 55 18506 10 10 12 mm zie 12 55 18506 12 12 14 mm 14 55 18506 14 14 16 mm 1 2 16 55 18506 16 16 19 mm 5 19 55 18506 19 19 22 mm 22 70 18506 22 22 26 mm 26 70 18506 26 26 30 mm o 30 70 18506 30 30 34 mm 0419 34 75 18506 34 34 39 mm 39 75 18506 39 39 45 mm 45 90 18506 45 45 51 mm 2 51 90 18506 51 51 57 mm 1o 28 _ 57 100 18506 57 57 63 mm 63 110 18506 63 63 69 mm 18506ins eps 69 110 18506 69 69 75 74 110 18506 74 74 80 mm 78 110 18506 78 78 87 In addition to the standard dies a wide range of special dies is available on request Selecting the die set P51 Use only original Finn Power die sets in Finn Power crimping machines Refer to the fitting manufacturer s specifications for proper crimping diameter for the fitting Each die set has its own crimping range Follow it to assure the roundest possible crimping result For standard die sets the adapter dies must be installed in the machine s master dies The minimum crimping diameter D is marked on each die set Example with die set No 18506 10 the minimum crimping diameter is 10 mm D L Die set No Crimping range 10 55 18506 10 10 12 mm 12 55 18506 12
21. ed on a Finn Power table the four shoes under the machine are removed The table with assembly instructions is packed separately The crimper may be installed on some other table as well provided it is sturdy and broad enough or it has been fastened on the floor so that it cannot fall over Furthermore there must be a hole in the table to enable emptying the oil tank through the drain plug P20 P21 and CC22 models x 558 560 Insta_32 eps P32 and P51 models x 625 y 560 WARNINGS General The machine is intended for professional use It is to be operated only by a trained operator who has understood the dangers involved in the operation Openings between the dies exceed 6 mm thus being large enough to let fingers go between the dies and get crimped It is therefore ABSOLUTELY necessary to follow operating instructions and warnings indicated by the stickers on the machine when changing dies and crimping fittings Danger zones 003199 eps WARNING 1 Do not put your hands inside the dies while the motor is running 003306 eps WARNING 2 When crimping a fitting hold the hose far enough to avoid crimping your hand WARNING 3 Dies open and close by depressing the hand emergency push buttons at both ends of the valve Do not touch these push buttons during normal operation 003002 eps WARNING 4 High voltage The electric box is to be opened only by a professional electric
22. g a larger Opening The allowable crimping range is shown in the figure Insert the fitting between the dies from the front side of the machine to enable crimping between the back of the dies Insert also large fittings that are as long as dies from the front side in which case the front part of the fitting is settled between the back of the dies Swaging force Allowable swaging range 201816141210 8 6 4 2 0 Allowable crimping range for the CC22 machine Crimping MS control WHEN CRIMPING A FITTING HOLD THE HOSE FAR ENOUGH TO AVOID CRIMPING YOUR HAND After installing the proper die set and adjusting the crimping diameter insert the hose and fitting between the dies Depress and hold down the crimping push button until the preset diameter has been reached The crimping movement stops automatically and light goes on in the crimping push button Depress the retraction button and take the crimped assembly out Check the result and measure the diameter If necessary correct the scale value and crimp again To enable faster crimping and reliable results in the future make a chart of the diverse hose fitting combinations and the corresponding die sets and dial adjustment values die opening Swaging force Allowable swaging range 0 die opening 201816141210 8 6 4 2 0 Allowable crimping range for the P51 machine Keephose eps Crimping IS AS VS controls WHEN CRIMPING A FIT
23. hdrawing the fitting from the stop device before it is gripped by dies If need be dies can be opened by using retraction button 6 Crimping goes on when the fitting is repressed against the stop device After reaching the crimping diameter dies return to the retraction position irrespective of whether the fitting is pressed against the stop device or not Vs s top wmf FOOT PEDAL pun Crimping starts when the foot pedal is pressed The movement be interrupted by lifting the foot from the pedal If need be dies can be opened by using retraction button 6 Crimping goes on when the foot pedal is repressed After reaching the crimping diameter dies return to the retraction position irrespective of the position of the foot pedal TOOL CHANGE E The VS control advises the operator to change the die set See VS control page 11 Covers P32 The rear of the crimping head is covered by a housing protecting the operator from the crimping hazard between rear flange and cylinder KEEP THIS COVER HOUSING IN ITS PLACE DURING CRIMPING Test run MS IS AS controls e Start the motor e Set the crimping diameter dial to 0 0 e During the first crimping cycles air in the cylinders may make the piston dies move irregularly and at high speed Cycle the press a few times till the motion becomes even e To avoid accidents make sure that there are no foreign objects between the dies e n case the dies do not move in either direction
24. he retraction button until maximum retraction is reached Stop the motor Prior to installing dies clean the contact surfaces of both the die set and master dies properly to avoid damaging the surfaces Insert the die with the die set pin into the master die die number always towards you After installing all the dies make sure they are straight and properly seated in the master dies Remove the die by turning it round the die set pin and pulling it parallel to the die set pin so that the die set pin comes out of the hole P50leva hgl 15 Setting the crimping diameter MS 10 11 12 From the crimping diameter chart on the electric box door you can see the die set numbers and the corresponding crimping ranges The upper section of the chart shows the corresponding dial position for each crimping diameter in the columns Crimping diameters in the grey zone of the chart not recommended 12 13 14 14 15 16 17 The crimping diameter dial has 16 17 18 19 been calibrated at the factory so 19 20 21 pu that when the dial is set at 0 0 24 5 26 DIE SIZE the resulting diameter will be the minimum diameter of the die set 31 37 installed i e with die set No 20 37 38 42 16 the crimping diameter will be 44 16 No 20 19 gives diameter of 19 mm etc Each full turn clockwise of the adjusting
25. ian High pressure Swaging hazard Warning 4 cylinders and pipes hatched area Warning 1 IN Warning 2 O fiy Si INN DOWER CON AN C7 e T P20dange eps High pressure Swaging hazard Warning 4 cylinders and pipes hatched area Warning 1 Warning 2 FINN B WER WE Warning 5 P32var hgl WARNING 5 P32 model High pressure Swaging hazard Warning 4 sylinders and pipes hatched area The rear of the crimping head is covered by a KN housing protecting the operator from the crimping hazard under the housing between panacea E rear flange and cylinder Do not remove this housing Waming 2 keeptool eps Warning 3 WARNING 6 When changing dies with the quick change m EE tool hold the handle as shown in the above figures Make sure your hand will not get P50var hgl between the dies COMMISSIONING Oil fill Fill the oil tank to centre line of the indicators in the dipstick with hydraulic oil like Shell Tellus T46 or equivalent Volume of the tank is 32 litres P51 model 50 litres It is recommended to pump the oil into the tank through a 20 u filter because new oil in drums is not pure Electrical connection CAUTION Check that the machine voltage see type plate is equal to your supply voltage For proper installation to local code consult a licensed contractor Bring the supply cable i
26. ither 1 2 mm before the set crimping diameter or at a pressure of approx 100 bar depending on which one is reached first The deceleration function is fully automatic Re calibration of crimping diameter dial MS control NOTE The crimping diameter dial has been calibrated at the factory during test run 1 Re calibrate the crimping diameter with ferrule seamless steel tube 2 25 mm wall 2 mm by using the die set No 20 19 P20 P21 CC22 or the die set 32 19 P32 P51 2 Set the dial at 1 0 so that the crimping diameter will be 20 mm see the adjacent picture and lock the dial Crimp the ferrule and measure the real diameter 3 Remove the control dial avoid to turn the dial shaft at the same time 4 Open the dial lock and set the real diameter into it diameter of ferrule relock it and install back 5 Turn the dial to right diameter and crimp another ferrule Now the machine has been calibrated and the real diameter should be the same than the diameter which state on the dial If not repeat from point 2 and be more careful when handling the dial 6 After the adjustment the crimping result should be the minimum nominal crimping diameter of each die set with the dial at 0 0 STOP LEVER LOCKING 10 turn uusi eps 23 TROUBLESHOOTING Troubleshooting is to be carried out by a serviceman TROUBLE POSSIBLE CAUSE ACTION Machine will not start 1 No electric supply Check fuses and supply cable connections
27. itting is repressed against the stop device After reaching the crimping diameter dies return to the retraction position irrespective of whether the fitting is pressed against the stop device or not Autopres wmf FOOT PEDAL Crimping starts when the foot pedal is pressed movement be interrupted by lifting the foot from the pedal If need be dies can be opened by using retraction button 7 Crimping goes on when the foot pedal is repressed After reaching the crimping diameter dies return to the retraction position irrespective of the position of the foot pedal Footpdiwinf CRIMPING DELAY In automatic modes a crimping delay can be set in order to improve the forming of the fitting The delay is activated by turning the mode selector to the delay position which makes the signal lamp beside the symbol light After this the mode selector is turned to a position indicating the intended mode of crimping The delay has been set to last approx 2 seconds It occurs after the crimping diameter has been reached but before the retraction movement i e the dies are kept closed for the time of delay after which they are opened To inactivate the delay turn the mode selector briefly to O postition or stop the motor sickens 4 SEMI AUTOMATIC CRIMPING This button starts crimping movement provided that master dies have reached the set retraction position signal lamp 8 is illuminated and semi automatic mode has been selected
28. movement 1 Select MANUAL MODE 2 Set the required crimping diameter 3 Insert the fitting 2 between the dies 1 to the correct position as shown in the figure 4 Crimp the dies lightly until they hold the fitting properly 19 20stopp jpg p5O0stop hgl E 7h m 9 gt P20 21 and P32 models CC22 and P51 models 5 P20 P21 and P32 models Loosen the locking nut 3 and push the stop device 4 against the fitting so that the spring loaded stop device is compressed making the limit switch inside it actuate Tighten the locking nut CC22 and P51 models Loosen the locking lever 3 and push the stop device 4 against the fitting so that the spring loaded stop device is compressed making the limit switch inside it actuate Tighten the locking lever Open the dies until the fitting loosens Select AUTOMATIC MODE When the stop device is pressed the machine performs a crimp and returns to the set retraction The movement stops if the fitting is not adequately pressed against the stop device If need be dies can be opened by using the retraction button 10 After dies have gripped the fitting the crimping movement can be stopped only by the emergency stop push button 11 Make sure that there are no foreign objects between the dies 12 a test crimp by pressing the fitting against the stop device 13 Check the crimping diameter and correct the position of the stop device if necessary
29. n the dies will open until the button is released or the maximum retraction is reached Crimping diameter dial Die chart with crimping diameter range for each die set and corresponding dial adjustment values HN P32Mkl P32MKI hgl The main operating area of the machine is in front of the controls Control identification IS AS VS controls 1 Control panel 2 Supply disconnecting device for starting and stopping the motor The device is used to disconnect the machine from power supply However the undervoltage trip can be made dead only by disconnecting the plug or supply cable from the mains When the stop device is pressed the dies will perform a crimping cycle When the foot pedal is pressed the dies will perform a crimping cycle Optional IS AS models Die chart with crimping diameter range for each die set and corresponding dial adjustment values P32_kayttolaitteet P32iskl hgl The main operating area of the machine is in front of the controls Control panel IS AS FINNPOWER S _ 8 D 2 E 6 P20aepan eps 1 SUPPLY DISCONNECTING DEVICE The supply disconnecting device starts and stops the motor It is used to disconnect the machine from power supply However the undervoltage trip can be made dead only by disconnecting the plug or supply cable from the mains In case of power failure the motor stops and the handle turns to the so c
30. n through the hole in the side panel of the electric box Secure the cable with a stress relief plug 3 phase Connect the phase conductors to the respective L1 L2 and L3 terminals in the supply disconnecting device Connect the earth connection to the ground terminal on the fixing plate Check the connection against the wiring diagram enclosed in the spare parts list Check that the motor rotation is parallel with the arrow on the tank close to the motor In case the motor rotates in wrong direction two phase conductors in the supply disconnecting device must be interchanged 1 phase Connect the phase and the neutral to the respective terminals in the supply disconnecting device Connect the earth connection to the ground terminal on the fixing plate Check the connection against the wiring diagram enclosed in the spare parts list Quick Fix package Included with the machine there is a Quick Fix package which has some basic parts for that machine model OPERATION Control identification MS control 1 Supply disconnecting device for starting and stopping the motor The device is used to separate the machine from power supply However the undervoltage trip can be made dead only by disconnecting the plug or supply cable from the mains As long as the crimping push button is depressed the dies will close until the button is released or the preset crimping diameter is reached Retraction button When depressed and held dow
31. nd open the dies to maximum retraction e Insert the pins of the tool into the die set in the die table turn the tool clockwise and pull the whole set out Fig 1 next page e Hold the handle of the quick change tool as shown in figures 1 and 2 and make sure your hand will not get between the dies e Mount the die set between master dies Fig 2 and start closing the dies TO AVOID DAMAGING MASTER DIES MAKE SURE THAT ALL DIE SET PINS HIT IN THEIR HOLES e Close the master dies completely until the pins are locked in their places Fig 3 Remove the tool The dies are now ready for use Fig 4 e Die set is removed from the master dies in reverse order close the dies insert the tool into the die set open the master dies and place the set back in the die table QC homma eps 14 QUICK CHANGE VS OPTION An optional Quick Change Tool Base enables storing die sets under the machine Die sets can be installed into the master dies with a quick change tool one set at a time Before installing dies make sure that the master dies are clean STOP THE MOTOR PRIOR TO CLEANING DIES Select TOOL CHANGE MODE See also VS control Chapter Tool change screen on page 11 Open the dies to maximum retraction Insert the pins of the tool into the die set in the die table turn the tool clockwise and pull the whole set out Fig 1 Hold the handle of the quick change tool as shown in figures 1 and 2 and make sure your hand will not
32. one of the chart are not recommended CHECK 2 NEXT The crimping diameter dial has been calibrated at the factory so that when the dial 37 is set at 0 0 the resulting 42 diameter will be the 47 minimum diameter of the die 53 set installed i e with die set 60 No 20 16 the crimping diameter will be 16 mm No 20 19 gives a diameter of 19 apenan JEAN MEW eps The crimping diameter chart P20 P21 22 mete The crimping diameter 5 x 7 7 4 L 6 l L 7 x L 7 d 3 els els 714 1 s 9 10 0 10 0 10 0 10 10 0 10 0 10 0 10 0 10 turned clockwise In 0 IS models one turn is min 1 2mm 3 4mm 5mm 7 8mm 9mm equivalent to a 1 mm change in the crimping diameter In AS models the diameter change is 1 mm between two digits The measuring scale of the dial is divided into divisions of either 0 01 mm in IS models or 0 1 mm AS models EXAMPLE The crimping _ gt __ Ee NEXT diameter of the fitting should UM DIE SIZE be 20 6 mm Select die set No 20 19 min crimping diameter 19 mm according to the die chart Turn the IS dial to position 1 60 upper scale 1 lower 60 The AS dial is turned to position 1 6 This setting will give the crimping diameter 20 6 mm 19 1 6 mm The machine has been calibrated at the factor
33. or use fitting types of the fitting manufacturer 13 PRESSURE SWITCH AND CRIMPING DELAY Pressure switch function and crimping delay on off See VS control page 9 14 RECALL OF STORED CRIMPING DATA The crimping data of a certain fitting type can be recalled from the control unit memory See VS control page 15 STORING OF CRIMPING DATA Crimping data are stored in the memory for the next time to be used It is worth while naming a fitting type to facilitate finding it again See VS control page 8 16 SETUPS Set ups of crimping delay pressure switch mm inch and calibration See VS control page 10 10 17 MODE SELECTION See VS control page 9 MANUAL Master dies be opened by pressing retraction button 6 and closed by pressing crimping button 5 Manual mode is used when changing dies and adjusting settings Ees taas wmf SEMI AUTOMATIC C Crimping movement gets started when the semi automatic button 4 is pressed The movement can be interrupted by releasing the button If need be dies can be opened by using retraction button 6 Crimping goes on when the button is repressed After reaching the crimping diameter dies return to the retraction position irrespective of whether the button is pressed or not Cycle wmf AUTOMATIC Crimping starts when the fitting is pressed against the stop device The movement stops if the stop device is not adequately pressed by the fitting It can also be stopped by wit
34. pacity Sound pressure level Enclosure class Closing speed of master dies Motor power Voltage V Current A Fuse A Motor power Voltage V Current A Fuse A in mm mm l min bar kN per hour dB A mm s kW kW IP 54 2 7 Frequency 50 Hz 4 200 20 5 35 230 15 5 25 400 8 6 20 l Frequency 60 Hz 4 8 210 20 2 35 230 15 2 25 400 8 2 20 Special diameters and profiles to customer s specifications Overall dimensions Weight 178 kg excluding oil ES 10 15 1 5 230 12 6 16 1 5 230 12 5 16 236 2 mittapurroe 436 29 READ THE INSTRUCTIONS THOROUGHLY SECURE SAFE AND CORRECT OPERATION OF THE MACHINE Technical data P51 Capacity Crimping diameter range Max opening Pump Max pressure Crimping force Theoretical production capacity Sound pressure level Enclosure class Closing speed of master dies max Motor power Voltage V Current A Fuse Motor power Voltage V Current A Fuse A in mm mm l min bar kN per hour dB A mm s kW kW with complete standard die equipment Special diameters and profiles to customer s specifications Overall dimensions 3 phase 2 7 industrial hose 4 4 120 46 18 6 300 2800 720 71 54 9 2 Frequency 50 Hz 4 230 15 3 25 400 8 8 20 Frequency 60 Hz 4 8 230 15 2 25 400 8 7
35. r dies through 16 grease nipples using a compressor gun alike as CC22 greasing Apply the grease to the conical surface at the back of the die with a small brush alike as 22 Lubricate often with a small amount of grease rather than seldom with much grease Do not grease the piston rod 21 Greasing 22 Fig 1 Fig 2 Open the dies to maximum retraction Lubricate the surfaces daily with pressure proof grease like Molub Alloy OG H or equivalent Lubricate the front side of the die through the grease nipples using a compressor gun see fig 2 Apply the grease to the conical surface at the back of the die with a small brush see fig 1 Lubricate often with a small amount of grease rather than seldom with much grease Do not grease the piston rod Oil change e Empty the tank of oil through the draining plug under the tank e Handle the waste oil according to law e Fill the tank to centre line of the indicators in the dipstick of the filling cap e Oil tank volume 32 litres P51 50 litres e Recommended oil Shell Telus T46 or equivalent e Change hydraulic oil after the first 500 hours of operation and every 1000 hours thereafter Filling cap e tis recommended to pump the oil into the tank through a 20 u filter because new oil in drums is not pure pA e oil has run out on the floor wipe it away Ln Filter change P20 P21 P32 CC22 Filter e Open the tank cover as shown in the figure
36. rger when the dial is turned clockwise 11 CRIMPING DIAMETER CONTROL The crimping diameter is defined by means of this vernier dial and the die set that is used The dial covers 0 10 mm The measuring scale is divided into divisions of either 0 01 mm or 0 1 mm The crimping diameter increases when the dial is turned clockwise If the dial is of multi turn type as in IS models one turn is equivalent to 1 change in the crimping diameter In AS models the diameter changes by 1 between two digits Control panel VS EE a 7 lt 2 0 01 28 4 O 1______ 11216 IINE FINN POWER E Me 00000 Oo 6 amp 9 P20vs eps 1 SUPPLY DISCONNECTING DEVICE The supply disconnecting device starts and stops the motor It is used to disconnect the machine from power supply However the undervoltage trip can be made dead only by disconnecting the plug or supply cable from the mains In case of power failure the motor stops and the handle turns to the so called TRIP position Restart the machine by turning the handle first to O position reset and after that to l position In an emergency the supply disconnecting device is used as an emergency stop 2 ENTER BUTTON E 3 SELECTOR All selections and control functions of the VS control are performed by means of the selector and enter button E The desired display adjustable from the selector is selected by t
37. the crimping diameter dial is plugged in IS AS models In automatic modes the dies must be in the retraction position signal lamp 8 illuminated otherwise the crimping cycle will not get started VS model If the motor is running but the machine does not crimp check that the crimping diameter dial is plugged in If still not working contact a serviceman PREVENTIVE MAINTENANCE Greasing P20 P21 P32 The following maintenance operations can be performed by the operator according to the instructions below However electrical works and repairs like changing seals or the pump must only be carried out by a qualified specialist PRIOR TO ANY SERVICING OPERATION TURN THE SUPPLY DISCONNECTING DEVICE TO POSITION 0 BEFORE CHANGING THE MOTOR CIRCUIT BREAKER OR UNDERVOLTAGE TRIP DISCONNECT THE PLUG OR SUPPLY CABLE FROM THE MAINS Open the dies to maximum retraction before servicing Greas_32 eps Lubricate the inner surface of the conical flanges daily with pressure proof grease like Molub Alloy OG H or equivalent Apply the grease to the conical surfaces at the front and back of the die with a small brush Lubricate often with a small amount of grease rather than seldom with much grease Do not grease the piston rod Greasing P51 Set the crimping diameter dial at 0 0 Close the dies and stop the motor Lubricate the master dies daily with pressure proof grease like Molub Alloy OG H or equivalent Lubricate the maste
38. uaranteed against defects in material and manufacture Within the limits of the guarantee the defective part will be replaced with a new one or when possible repaired free of charge The guarantee is valid for 12 months after commissioning yet for a period not exceeding 18 months after delivery ex works Alaharma Finland The guarantee does not compensate for damage due to improper use overload neglect or normal wear Working and travelling costs as well as freight charges caused by guarantee repairs are not covered by the guarantee Guarantee repairs shall be carried out at Lillbacka Powerco Oy Alaharma Finland or by an authorized Finn Power service In case guarantee repair is demanded the customer has to prove that the machine is under guarantee LILLBACKA POWERCO OY DO NOT WARRANT FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGAES OR FOR ANY OTHER LOSS DAMAGE OR EXPENSE OF ANY KIND INCLUDING LOSS OF PROFITS TECHNICAL DATA Technical data P20 Capacity Crimping diameter range Max opening Pump Max pressure Crimping force Theoretical production capacity Sound pressure level Enclosure class Closing speed of master dies Motor power Voltage V Current Fuse Motor power Voltage V Current A Fuse in mm mm l min bar kN per hour dB A mm s kW kW 3 phase 1 4 61 25 8 275 1370 850 71 54 2 5 Frequency 50 Hz 3 200 16 25 230 11 7 20 400 6 7 16
39. urning the selector and activated by pressing E button The display then gets a bold shaded outline and the display value can be modified by turning the selector The new value comes into force after pressing E The display turns partly shaded again after which another display can be selected by turning the selector 4 SEMI AUTOMATIC CRIMPING This button starts crimping movement provided that the symbol of semi automatic crimping is shown the mode display cycle wmf 5 dies will close when this button is pressed The dies move until the button is released or the set crimping diameter has been reached When using this button manual mode must be selected 6 RETRACTION BUTTON The dies will open when this button is pressed The dies open until the button is released or the set retraction diameter has been reached This button can be used either in manual mode or in semi automatic and foot pedal modes in a situation when you want to open dies in the middle of crimping 7 CRIMPING DIAMETER The crimping diameter is defined by selecting a value on this display and by means of the die set that is used The crimping range extends from the minimum crimping diameter of the smallest die set programmed up to the maximum crimping diameter of the largest die set programmed It is divided into divisions of 0 1 mm In addition the crimping diameter can be modified by correction adjustment 8 DIE SET
40. y with 40 bar pressure This means that when you are crimping a fitting requiring 40 bar pressure the measuring scale of the crimping diameter dial provides an accuracy of 0 1 mm possible elastic recovery of the fitting not regarded When fittings requiring higher pressure are crimped the crimping diameter may become larger than the value on the scale due to machine deflections Then the crimping diameter has to be corrected by changing the scale value 32chart eps The crimping diameter chart P32 P51 Setting the crimping diameter VS While the crimping diameter display is surrounded by the cursor activate it by pressing E Select the desired crimping diameter by turning the selector and press E Check the die set used and change it if need be When required set the retraction diameter in the same way The machine has been calibrated at the factory with 40 bar pressure This means that when you are crimping a fitting requiring 40 bar pressure the measuring scale of the crimping diameter dial provides an accuracy of 0 1 mm possible elastic recovery of the fitting not regarded When fittings requiring higher pressure are crimped the crimping diameter may become larger than the value on the scale due to machine deflections Then the crimping diameter has to be corrected using the correction function Operation limitations P51 CC22 The sheerer cone in the master die and piston is not meant for crimping but only for achievin
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