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NC40-640 Crimping Machine
Operation manual
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Contents
1. Structure and work principal.
2. Specification details.
3. Electric control.
4. Operation
5. Maintenance
6. Safety
7. trouble shooting.
8. appendix.
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1. Structure and work principal.
987
constructionNEKON
Off
On
POWER
DIE-BACKING)
TIMEREGUIATOR
A UT O M AN UA L
2
4
3
5
6
1
1. ring cylinder 2. Sliding block 3. Ring spring 4. Pressing dies 5. Positioning
magnetic plate 6. Oil tank 7. Control panel 8. Pressure Meter 9. Electric box
Work Principal
The annular piston pushes the sliding block sliding in the conical sliding path on the
inner wall of the annular cylinder, they taper fit with each other so when the sliding
blocks move forward, they also push the pressing dies into the axis direction which
press on the work piece.
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2. Major specifications
rebar sizes for the couplers 12 -40
Pressing die moving distance 15MM
Hydraulic pressure 31.5Mpa
Pump capacity 90L/MinOil type 46# hydraulic oil
Oil Tank volume 480L
Cooling system Air cooling
Moter power 11kW
Power Supply 380V 50Hz
Machine weight (kg) 1800 kgs
Machine dimensions 1320x850x1500mm
3. Electric control
3.1 Control Panel:
CYLINDER
AUTO MANUAL
6
5
PRESS RELEASE
POWER
Off
On
NEKONconstruction
MOTOR
4
On Off
3
DIE-BACKING)
TIMEREGUIATOR
21 87
1. Motor On 2.Motor Off 3.Release (dies open) 4.Press (Dies close) 5. Manual
mode 6. Automatic mode 7. Die release meter 8. Main power Switch
3.2 The electric principal refers to the attached electric diagram.
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4. Operation
4.1 input oilinput 480L 46# hydraulic oil into the tank (The oil level meter should be
above 2/3)
4.2 Power switch on
Switch on main power. Press the motor on button, checkwhether the motor rotates along the direction of its arrow to make sure the motor
rotation direction is correct.
4.3 Test the buttontest each button on the control panel to see they work correctly.
4.4 install the pressing dies and the positioning device
After finish the above initial check up, ensure the machine is in manual mode,
press the release button to move the sliding blocks backword to the end of its
position (biggest opening of the sliding blocks), then stop the motor and startinstalling the pressing dies as follows:
Use 17mm spanner to loosen the 8 fixingbolts
Select the correct dies, check the dies areintact and no cracks, the handle is not loose,to make sure they are in good condition.
Put the pressing dies on the sliding blocksby the sequence from the bottom to the top,make sure the handle sit in the positioninghole on the sliding block.
Move the sliding blocks to its max.opening by manually operate therelease button and then stop the motor.
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Set up the positioning device
Install it back on the machine.
Change the positioning bar (differentlength) according to the coupler size.This positioning bar stops the rebar in thecoupler when the coupler end touchesthe positioning plate. So this is to set uphow much length the rebar goes into the
coupler.
Take out the positioning device.Release the fixing bolts of the positioningdevice on the back of the machine.
Put all the 8 pressing dies in, tighten thefixing bolts a little bit and make sure the 8dies are in good position.
Switch on the motor, operate manually to(press the press button) close the slidingblocks so the press dies close to itsminimum opening. Stop the motor andtighten the fixing bolts.
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4.5 Adjust the hydraulic pressurePress down the red knob on the pressure meter
and at the same time turn the pressure indicator (hand) to the desired position, then
release holding down the red knob so the desired pressure is set.
Insert the coupler with the rebar inside,make sure the coupler touches thepositioning plate and the rebar touches thepositioning bar, then the right pressing canbe reached.After position calibration, tighten the lock
bolt to lock the positioning device.
Switch on the motor, put in a coupler, closethe pressing die a little by manualoperation, then adjust the position of thepositioning plate by moving the wholepositioning device forward or back work tillthe right position reached. This is to set upthe length of pressing on the coupler.
Release the positioning lock bolt so thepositioning device inside can moveeasily.
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4.6 Adjust the release timer
Its not necessary to let the pressing dies (sliding blocks) always return to their very
beginning position as this would waste time if the opening is already big enough to
receive the certain size of the coupler. The release timer is to set the time for thecylinder to return so a proper time for the cylinder to return means once the opening
is big enough for the certain coupler, the pressing dies will stop open more and the
next press can start automatcically (This function works only in automatic mode).
Enter into automatic mode by pressing the
Auto button. Set up the desired release time
(the time for the cylinder to return). Please
refer to the attached table to choose the
proposed release time.
4.7 Automatic mode.
Once the manual operation (pressing press button in manual mode) reaches the
satisfactory result of coupler pressing and the release timer is properly set, the
machine can enter into Automatic mode by pressing automatic button. In
Automatic mode, after put in the coupler and rebar in place in the machine, just
press the foot pedal then the pressing and release process shall complete
automatically.
5. Lubrication and maintenance.
5.1 The machine must be placed on ground horizontally.
5.2 Important: Before each batch production, lubricating the sliding paths (the 8
sliding paths on the inner wall of the annular cylinder, just lift the sliding block a
little it can be seen) and the sliding blocks with grease. Set the pressure to theminimum, release the sliding blocks (pressing dies) to the maximum, apply the
grease on the inner wall of the cylinder, also lift the sliding block a little bit so the
grease can be put into the sliding path with a grease gun. Then close and open
the pressing dies several times without any load. After proper greasing, wipe out
all the grease outside to ensure the pressing dies are clean.
5.3 In case of leakage of the hydraulic oil, replace the hydraulic seals.
5.4 The hydraulic oil is 46#. The best temperature should be around 30~35.
5.5 Check the sliding blocks and pressing dies regularly, ensure they are in good
position and condition..
5.6 Clean the oil system, electron valve, overflow valves regularly.
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6. Safety check up.
6.1 after switch on the motor, check around the machine to ensure no leakage of the
oil before starting work.
6.2 Stop the motor before change dies.6.3 during pressing process, never inert hands into the dies.
6.4 The machine can only be maintained by professional personnel.
6.5 Dont press the machine without load, dont work long time with pressure more
than 30 Mpa (Max. 31.5Mpa)
7. Trouble shooting and solution
Problem Cause Solution
The motor rotates the wrong
direction
Change the phase of the power supply
restriction hole of the overflow valve
jammed
clean the restriction hole
overflow valve damaged repair or replace the overflow valve
No hydraulic pressure
or low pressure
pump damaged repair or replace the pump
oil level lower than the required refill the oil
pump damaged repair or replace the pumpThe noise of the pump is
too bigshaft coupler damaged repair or replace the shft coupler
problem of the power supply for theelectromagnet
check the power supply to theelectromagnet.
the reversing valve stuck or
damaged
repaire or replace the reversing valveReversing valve does
not work
no pressure of the hydraulic system adjust the overflow valve to increase
the pressure
big noise during
pressing (dies, sliding
blocks)
bad lubrication in the sliding path proper lubrication.
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Appendix 1. Recommended parameters for standard couplers:
D*
d1
LL
e
f
d1
d dDD
L* L*
D*
f
e
Thread
M
Before
PressingRecomd. Recomd. After pressing
Recomd.
PressureDie
CouplerRebar
d D L e f D* L* Mpa) (mm)
DSD10 10 12 17.5 47 28 23 14.3-14.6 52 2.3-2.6 12
DSD12 12 16 22 58 34 30 17-17.5 64 3-3.3 14
DSD14 14 18 26 68 38 34 20.5-21.5 74 4-4.5 16
DSD16 16 20 28 77 46 38 22-23 84 5.5-6 20
DSD18 18 22 31 87 50 41 24.5-25.5 95 6.5-7 20
DSD20 20 24 34 94 53 44 27-28 103 7.5-8 24
DSD22 22 27 38 101 58 48 32-33 110 8-9 24
DSD25 25 30 42 114 67 54 34-35 122 9.5-10.5 30
DSD28 28 33 46 125 70 58 39-40 132 12-12.6 36DSD30 30 36 50 138 80 65 41-42 147 13.5-14.5 36
DSD32 32 42 57 149 81 55 49.5-50.5 160 16-17 45
DSD34 34 42 57 157 89 74 49.5-50.5 169 18-19 45
DSD40 40 48 67.5 182 104 85 59-60 194 22-23 55
The above parameters are recommended according to our couplers and the normal
conditions of our machine, tests are needed for the client to determine the best
parameters for their work.
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Appendix 2.Electric diagram for 11kw hydraulic station.:
SB1
AC contactor
relay-2
AC contactor
thermal relay
button wit
lamp Red
0.4mm2
Red
motor start/stop
motor start/stop
0.5mm2
Blue
0.5mm2
Red
2
1
L1
emergency
stop
button with
lamp Green
relay-1
start
relay
SB2
3
L3
LA
LB
LC
U V W
M
~pump motor
11KW
Circuitbreaker
AC contactor
thermal relay
control
transformer
0V
4
24V
L2
electric
bridge
AC380V
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Electric diagram for 11kw hydraulic station.
diod
button
with
lamp
button
with
lamp
button
with
lamp
relay2-1
relay3relay2Time relay
release
time
eletro-magnetic valve
for die close
eletro-magnetic
valve1
diode
5
0V24V
Controler
relay of
die open
relay of
die close
24V
HL6
indicator ofdie open
HL5
indicator of
die close
HL4
indicator ofautomatic
Time
relay
electro
connection
pressure
gauge
electro
connection
pressure
gauge
Die
open
(Release)
Dieclose
(Press)
auto-
matic
button
with
lamp
manual
Y08Y07Y06Y0524+Y04
COM X12X11X10X09COMCOM
HL3
indicator of
manual
release
time
Y03Y02Y0124+0V24+
X08X07X06X05X04X03X02X01
0V
24V
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panel diagram
Die close (Press) Die open (Release)
manual automatic
Valve
for
Die
open
Valve
for
die
close
Note:COM,X3 conn
list of connecting terminal
0V7
Y4
COM X4
24VY3
COM X324V
Y2
COM X2
24V
lamps on the panel
0V65Y5Y4Y3Y224V
X6X5COM
X4X3X24321
40V
21
0V33
Y1
2
Stop
pressure gauge
X6COM
24V
Y5COM X1
24V
release time adjustment
Start
overflowvalve
buttons on the panel
Y1X1COM
0V
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Appendix 3.Hydraulic diagram:
Check Valve
4DT
2DT1DT
oil level
indicator
overflow
valve
oil tank:480L
motor
shaft coupler
air filter
M3
air cooler
pressure gauge
M
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