www.mailleferextrusion.com 850 1010I.

2 - ENG

FORMING TOOL
DN16 - DN20 - DN26 - DN32
- Installation manual

850 2300J
780 0156A
780 0242A

Release date : 2011-11-07

  
Forming Tool DN16 - DN20 - DN26 - DN32

COMPULSORY!
Retain this document for later reference.

CAUTION!
Before handling the machine, each user is required to read the "Safety instructions"
document as well as this manual.
The safety instructions must be observed.

  

English version translated from the original version

MAILLEFER SA pursues a policy of continuous development. Consequently, we reserve the right to
modify or improve without notice any product featured in this manual. Moreover, MAILLEFER SA does
not accept liability for any errors in this document.

© 2011 MAILLEFER SA All rights reserved.

Rev. Date Author Notes

1 2010-05-07 RédaTech / MER New document.

New graphic charter.

2 2011-11-07 RédaTech / MER Addition of forming tools DN16, DN26 and DN32.
Maillefer SA address changed.

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 Forming Tool DN16 - DN20 - DN26 - DN32

Table of contents

1 Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Conformity with standards and directives . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Aims of the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Risks specific to the forming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Technical assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.1 Machine under warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.2 Machine outside warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.3 Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Checking received items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.2 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Transporting the packaged machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Transportation and positioning of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Setting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.1 Setting the width of passage of the strip . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.2 Strip-guide centring mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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 Forming Tool DN16 - DN20 - DN26 - DN32
Generalities

1 GENERALITIES

1.1 General information

The content of this document is based on the information available at the time of
publication.

The original version of the document was written in French.

The information contained within this document is the property of MAILLEFER SA ; is

has been compiled solely for internal use by the client and not for any other use; it is
forbidden to copy this information or send it to a third party.

1.1.1 Conformity with standards and directives

The “CE” marking indicates that this product conforms to European standards in terms
of safety, health, environment and user protection.

1.1.2 Appropriate use

The instructions in this manual must be observed, particularly the safety instructions.

1.2 Aims of the documentation

The documentation supplies information necessary for the appropriate use of the
machine. It informs the user so that the operation or maintenance procedures can be
performed effectively.

For security and environmental protection reasons, it is vital to follow the safety
instructions contained in the documentation.

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Forming Tool DN16 - DN20 - DN26 - DN32
Generalities

1.3 Risks specific to the forming tool

DANGER!
Risk of entanglement in rotating machine components.
 

FORBIDDEN!
Do not wear loose clothing, necklaces, rings or any other objects. Risk of getting pulled
into or getting wound up in rotating machine components.

COMPULSORY!
The use of protective gloves is mandatory when handling the strip.
 

COMPULSORY!
The use of protection goggles is mandatory when performing operations near the
welding station.

DANGER!
Friction rings - Mercotac earthing contain liquid mercury which presents a danger to
human health and to the environment.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Generalities

1.4 Technical assistance

The following information will be required when requesting technical assistance :

• machine identification (see identification plate) ;

• type of problem with the machine.

1.4.1 Machine under warranty

Please contact the project manager at Maillefer.

1.4.2 Machine outside warranty

Please contact the Customer Service Unit at Maillefer.

1.4.3 Address

MAILLEFER SA
Customer Service Unit
Tel. +41 21 694 44 13
Fax. +41 21 694 43 99
csuecu@maillefer.net

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Forming Tool DN16 - DN20 - DN26 - DN32
Generalities

1.5 Terminology

User
The user is the owner of the machine, whether he uses it himself as owner or whether
he has transferred it to a third party.

Operator
The operator is the person that carries out production operations with the machine.

Technical personnel
The term “technical personnel” includes all persons who are authorised to work on the
machine by virtue of their training and qualifications.
For example, work on the electrical components of the machine must be carried out by
a qualified electrician.

Qualification of personnel
The personnel will require different qualifications depending on the various types of
activities that must be undertaken on the machine.

Machine
The term machine refers to the forming tool.

Production line
A production line comprises one or several machines with defined functions for the
manufacturing of a product.

 Information
The terminology for the machine components is defined in the general description
found in the Operator Manual for the machine.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2 TRANSPORT AND INSTALLATION

2.1 Recommendations

CAUTION!
Observe the markings present on the packaging.

COMPULSORY!
Only technical personnel are authorised to install the machine.

COMPULSORY!
Safety shoes must be worn.

COMPULSORY!
The commissioning of the machine must be carried out by Maillefer SA authorised
personnel.

2.2 Checking received items

COMPULSORY!
All missing or faulty equipment must be mentioned on the transport documents. Notify
the transport company and supplier immediately.

 Information
In some cases, possible damage can only be observed when commissioning the
machine.

Check that all delivered equipment corresponds to the shipping list and that it is not
damaged.

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Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.3 Environmental conditions

To ensure the reliability of the machine, the following conditions are required :

• temperature . . . . . . . . . . . . . . . . . . . .: + 5°C to + 40°C ;

• relative humidity. . . . . . . . . . . . . . . . .: 10% to 90%, without condensation.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.4 Technical specifications

2.4.1 General specifications

Refer to the forming production table supplied with the machine for more information.

2.4.2 Electrical specifications

• Acceptable Mercotac current. . . . . . . 2x250 A.

2.4.3 Dimensions

DN16-DN20
357.1 mm

1780 mm 300 mm

DN26-DN32
357.1 mm

2180 mm 300 mm

850 2302J
780 0203A
780 0242A

Fig. 2-1

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Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.5 Transporting the packaged machine

CAUTION!
Take the centre of gravity of the packing case or pallet into account when moving it.

DANGER!
Avoid shocks when handling.
During handling, personnel must remain outside the work zone.

• Minimum lifting weight . . . . . . . . . . . .: refer to the shipping document which gives

the exact weight of the package.

850 2303J
780 0203A

Fig. 2-2:
Moving the packaged machine

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 Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.6 Unpacking

 Information
The forming tool is coated with a protective product. It must be cleaned after
unpacking.

A. If the machine is delivered in a packing case, remove the cover and then the side
panels.
B. Remove the plastic protective film and the protection elements surrounding the
machine.

850 2304J
780 0203A

Fig. 2-3:
Dismantling the packing case

C. Remove the components attaching the machine to the pallet.

D. Clean the machine with a cloth and isopropyl alcohol.

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Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.7 Transportation and positioning of the machine

CAUTION!
The equipment (electrical equipment in particular) must be handled with great care
after it has been unpacked.

CAUTION!
Take the centre of gravity of the machine into account when moving it using the lifting
system.

DANGER!
Avoid shocks when handling.
During handling, personnel must remain outside the work zone.

• Minimum lifting capacity. . . . . . . . . . .: 350 kg.

 Information
The forming tool is aligned with the welding unit using the stops mounted on the bench.

A. Place the forming tool on the forming bench.

B. Align the forming tool with the welding unit.

 Information
The forming tool is mounted on runners to facilitate movement on a flat surface.

C. Fix the forming tool to the bench with clamps.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

+

1H1

+

2H1

+

2H2

850 2305J

Fig. 2-4

Forming tool Slinging marker

DN16 - DN20 1H1
DN26 - DN32 horizontal forming 2H1
DN26 - DN32 vertical forming 2H2

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Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

2.8 Electrical connection

DANGER!
Risk of electrocution from the welding unit installed on the forming bench.

COMPULSORY!
The welding unit must be switched off before undertaking the connection.

A. Connect the earth 1 to the welding unit.

Refer to the welding unit manual for more details.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Transport and installation

Forming Tool
DN16 - DN20

Forming Tool
DN26 - DN32

1
850 2306J

Fig. 2-5

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Transport and installation

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 Forming Tool DN16 - DN20 - DN26 - DN32
Settings

3 SETTINGS

3.1 Recommendations

 Information
Adjustment and centering of the strip guide is done with the machine running.

DANGER!
Risk of entanglement in rotating machine components.

FORBIDDEN!
Do not wear loose clothing, necklaces, rings or any other objects.
Risk of getting pulled into or getting wound up in rotating machine components.

COMPULSORY!
The use of protective gloves is mandatory when handling the strip.

COMPULSORY!
The use of protection goggles is mandatory when performing operations near the
welding station.

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Forming Tool DN16 - DN20 - DN26 - DN32
Settings

3.2 Setting procedures

3.2.1 Setting the width of passage of the strip

A. Turn the handle 4 to adjust the width of passage of the strip (dimension L).

 Information
The guiding bearings 1 must brush against the strip when it is introduced into the strip
guide.

3.2.2 Strip-guide centring mechanism

The formed strip is welded end-to-end as it leaves the forming tool.

 Information
To ensure proper welding of the strip, the edges of the strip must be aligned with the
welding unit (A).

IMPORTANT!
Poor alignment of the edges of the strip with the welding unit (B) will prevent it from
being welded.

A. Loosen the locking nut 2.

B. Adjust the centering of the strip in relation to the tube using the adjusting nut 3.
C. Tighten the locking nut 2.

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 Forming Tool DN16 - DN20 - DN26 - DN32
Settings

1
L

4
3
2

A B

850 2307J
780 0203A

Fig. 3-1

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 MAILLEFER SA
Avenue du Tir-Fédéral 44
Case postale 254
CH - 1024 Ecublens
Suisse
www.maillefer.net