www.mailleferextrusion.com 850 1011I.

2 - ENG

FORMING TOOL
DN16 - DN20 - DN26 - DN32
- Operator 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.

Operator manual
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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 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Detailed description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.1 Strip guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.2 Horizontal station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4.3 Vertical station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Welding station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Operator work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.8 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Setting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Setting the width of passage of the strip . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Strip-guide centring mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 Essential care maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 Visual inspection of the forming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.2 Cleaning the forming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operator manual
850 1011I.2 - ENG Page 3/36
Forming tool DN16 - DN20 - DN26 - DN32

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Recycling the friction rings - Mercotac earthing . . . . . . . . . . . . . . . . . . . . . . . . . 34

Operator manual
Page 4/36 850 1011I.2 - ENG
 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.

Operator manual
850 1011I.2 - ENG Page 5/36
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.

Operator manual
Page 6/36 850 1011I.2 - ENG
 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

Operator manual
850 1011I.2 - ENG Page 7/36
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.

Operator manual
Page 8/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2 TECHNICAL INFORMATION

2.1 General information

The forming tool is used to form a tube from a flat strip of various metal alloys.

 Information
The forming tool is a component of the forming bench which also includes a welding
unit.

Operator manual
850 1011I.2 - ENG Page 9/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.2 Operating principle

The tube, which is coated with an adhesive layer, and the strip 1 are introduced into the
forming tool.

The horizontal stations 2 and vertical stations 3 consist of vertical and lateral rollers
respectively. These rollers have different profiles that are used to progressively format
the strip around the tube.

The welding station 4 holds the strip formed around the tube in place before welding.

The welding unit 5 is installed after the forming tool and is used to weld the edges of
the strip from end-to-end.

Operator manual
Page 10/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

1 2 3 4 5

Forming tool
DN16 - DN20

Station 0
Station 1
Station 2
Station 3
Station 4
Station 5
Station 6
Station 7
Station 8
Station 9
Station 10
Station 0
Station 1
Station 2
Station 3
Forming tool
DN26 - DN32 Station 4

Station 5
Station 6
Station 7
Station 8
Station 9
Station 10
Station 11

850 2308J
780 0203A
780 0242A

Fig. 2-1:
General operating principle of forming tool

Operator manual
850 1011I.2 - ENG Page 11/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.3 General description

1 Strip Guide
2 Horizontal forming station
3 Vertical forming station
4 Welding Station
5 Base plate
6 Runners for moving the forming tool on the bench
7 Lifting ring

Operator manual
Page 12/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

Forming tool
DN16 - DN20

1
2

Forming tool
DN26 - DN32

850 2309J
780 0203A
780 0242A
6
Fig. 2-2

Operator manual
850 1011I.2 - ENG Page 13/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.4 Detailed description

2.4.1 Strip guide

The strip guide centers the strip in relation to the tube.

1 Guiding rollers
2 Adjusting nut for centering the strip
3 Handle for adjusting the width of the strip
4 Guiding bearings

Operator manual
Page 14/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

Forming tool
DN16 - DN20

Forming tool
DN26 - DN32

2
1
3

850 2310J
780 0203A
780 0242A

Fig. 2-3

Operator manual
850 1011I.2 - ENG Page 15/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.4.2 Horizontal station

 Information
The horizontal stations are not interchangeable between each other.

1 Upper forming rollers

2 Lower forming rollers
3 Adjustment spacers for the thickness of the strip
4 Bearing housing

Operator manual
Page 16/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

Forming tool
DN16 - DN20

Forming tool
DN26 - DN32

1
4

850 2311J
780 0203A
780 0242A

Fig. 2-4

Operator manual
850 1011I.2 - ENG Page 17/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.4.3 Vertical station

1 Tube guide
2 Lateral forming rollers

 Information
The lateral forming rollers are not interchangeable between themselves.

3 Friction rings - earthing for the welding unit current return

4 Support for the vertical station
5 Lifting ring

 Information
The lower rollers are only fitted on the forming tool DN26 - DN32.

6 Lower rollers

Operator manual
Page 18/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

Forming tool
DN16 - DN20

Forming tool
DN26 - DN32

1 3

3
4

5 4
850 2312J
780 0203A
780 0242A

Fig. 2-5

Operator manual
850 1011I.2 - ENG Page 19/36
Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.4.4 Welding station

The welding unit holds in place the strip formed around the tube just before welding.

1 Welding unit support

2 Welding rollers
3 Tube with the formed strip

Operator manual
Page 20/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

Forming tool Forming tool

DN26 - DN32 DN16 - DN20

1
2

850 2313J
780 0203A
780 0242A

Fig. 2-6

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Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.5 Electrical components

1 Mercotac friction rings - earthing

2 Current return cables
3 Current return connectors

2
3
850 2314J
780 0203A
780 0242A

Fig. 2-7

Operator manual
Page 22/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.6 Operator work area

800 mm

850 2315J
780 0203A

Fig. 2-8

2.7 Noise level

The noise level generated by the forming tool is under 85 dB and complies with the EN
ISO 3744 and EN ISO 11201 directives.

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Forming tool DN16 - DN20 - DN26 - DN32
Technical information

2.8 Labelling

Figure 2-9 indicates the position of the safety labels on the machine.

COMPULSORY!
Ensure the safety labels on the machine are perfectly legible and clean.
If necessary, replace the labels with new ones and place them in the same location.

850 2316J

Fig. 2-9

Operator manual
Page 24/36 850 1011I.2 - ENG
 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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850 1011I.2 - ENG Page 25/36
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.

Operator manual
Page 26/36 850 1011I.2 - ENG
 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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Forming tool DN16 - DN20 - DN26 - DN32
Settings

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 Forming tool DN16 - DN20 - DN26 - DN32
Essential care maintenance

4 ESSENTIAL CARE MAINTENANCE

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Forming tool DN16 - DN20 - DN26 - DN32
Essential care maintenance

4.1 Maintenance schedule

Intervals Operation Reference

Check
Monthly Visual inspection of the Chapter 4.2.1 - Visual inspection of
machine functions the forming tool
Cleaning and replacement
Defined according Cleaning the forming Chapter 4.2.2 - Cleaning the
to the line tool forming tool
maintenance
schedule

Table 4-1

 Information
It is recommended to replace the bearings every 6,000 hours.

 Information
The intervals depend on the quality of the environment where the forming tool is
installed.

4.2 Maintenance procedures

4.2.1 Visual inspection of the forming tool

A. Check the condition of the bearings and the forming rollers.

4.2.2 Cleaning the forming tool

Equipment required :

• 1 off-the-shelf abrasive sponge.

A. Stop the forming bench.
B. Clean all of the rollers in contact with the tube and the strip.

Operator manual
Page 30/36 850 1011I.2 - ENG
 Forming tool DN16 - DN20 - DN26 - DN32
Troubleshooting

5 TROUBLESHOOTING

DANGER!
Never disconnect live cables or connectors. Always power the machine off before any
operation.

COMPULSORY!
Only technical personnel are permitted to perform these operations.

 Information
If the type of problem affecting the machine is not included in the list, or in case of
doubt, please contact Maillefer SA.

Operator manual
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Forming tool DN16 - DN20 - DN26 - DN32
Troubleshooting

The following list describes problems that can arise with the forming tool and how to
solve them.

Problem Cause Solution

The strip is not Alignment problem. Align the strip in relation to the
welded correctly. tube.
See Chapter 3.2.2 - Strip-guide
centring mechanism.
Problem with welding Poor current return. Check the connection of the
the strip. forming tool current return to the
welding unit.
Friction ring - earthing Replace the faulty friction ring -
damaged. earthing.
The strip is not A forming roller in a Replace the faulty forming roller.
correctly formed or is station is damaged. (Refer to the Maintenance
badly folded. Manual)
An axle bearing is Replace the faulty bearing.
damaged or jammed. (Refer to the Maintenance
Manual)

Table 5-1

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 Forming tool DN16 - DN20 - DN26 - DN32
Scrapping

6 SCRAPPING

COMPULSORY!
Only technical personnel are authorised to dismantle the machine for scrapping.

The machine must be scrapped in accordance with directive EU 2002/96/EC or the

environmental standards in force in the country of installation.

The materials comprising the machine must be separated and recycled in a waste
recycling centre that conforms with the legislation in force in the country of installation.
This will help to reduce the impact on the environment and health and safety and help
to promote recycling.

Contact your local recycling centre for more information.

Operator manual
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Forming tool DN16 - DN20 - DN26 - DN32
Scrapping

6.1 Recycling the friction rings - Mercotac earthing

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

COMPULSORY!
Friction rings - Mercotac earthing must be recycled in an approved collection centre for
handling mercury or, if necessary, returned to Maillefer SA.

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 Forming tool DN16 - DN20 - DN26 - DN32
Scrapping

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