Operating and Servide Manual 90126-IM

OPERATING & SERVICE MANUAL # 90126-IM Rev.
2/29/00
READ SAFETY RECOMMENDATIONS BEFORE OPERATING THIS TOOL
AIRETOOL OPERATION 302 South Center Street Springfield, Ohio 45506
Operation The Airetool Patented Roller Beading Expanders are designed to expand and bead firetube boiler tubes in one operation. This expander eliminates the secondary operation of beading the tube with a chipping hammer and beading chisel. The expander reduces shop noise levels and operator stress, thus increasing overall productivity. Tube Projection The tubes must have a uniform projection from the tube sheet of 3/16- 9/32 (4.75mm- 7.1mm) prior to beading the tube with the Airetool roller beading expander. The tubes must be staked or clamped at one end of the boiler with the opposite end having the 3/16-9/32 tube projection. To obtain the tube projection from the end of the boiler where the tubes were staked or clamped an internal wheel type boiler tube cuter must be used with the tube cutters collar positioned to obtain the tube projection. Reference Airetool series FTC Firetube Cutters for accomplishing this task. Failure to comply with the recommended tube projection will cause extreme side load pressure and reduce the expanders life. Lubrication The tubes and the roller beading expander must be clean and free of any debris prior to expanding. The Airetool beading expander is sold with lubrication, we call bead lube. This is the only lubrication that is to be used during the expanding process. This lubrication is water-soluble and is to be mixed with water at approximately twenty (water) to one (lubrication) ratio. After each expansion place the expander in the bucket of lubricant and swish it around until all the debris has been removed from the expander roller cavity areas. The expander must be kept cool and clean, or the beading roll will start galling the bead, making it unacceptable. This extreme heat will also decrease the expanders life. Beading Expander Set-up Measure the tube sheet hole ID, tube ID tube OD and the tube wall thickness. Then subtract the tube OD from the tube sheet ID, this will give you the clearance between the two. Then multiply the tube wall thickness by two and again by .10 (this is the expansion at 10%wall reduction). Next add the clearance, the wall reduction calculation to the non-expanded tube ID. This will give you the expansion of the tube at 10% wall reduction. See the chart below for additional reference.
Step A Measure tube sheet hole Step B Measure tube OD Step C Calculate clearance (A - B) Step D Measure tube ID Step E Calculate wall thickness (B - D) Step F Calculate 5% wall reduction (.10 x E) Step G Calculate finished rolled ID (C + D + F)
A B C D E F G
STEP EXAMPLE Tube Sheet Hole 2.032 - Tube OD 2.000" = Clearance .032" + Tube ID 1.810 2 x Wall Thickness .190" + 10% Wall Reduction .019" = Finish Rolled ID 1.861"
JOINT # 3
Beading Expander Set-up continued: After determining the final rolled ID, insert the expander into the tube that is to be beaded. Insert the mandrel into the expander, then tap the mandrels end slightly with a hammer until the expanders rolls come in contact with the tube ID. Per the example above we are expanding the tubes ID .051 to obtain the 10% wall reduction. For each 1 of mandrel travel, we obtain .041 in expansion, therefore by dividing the total expansion (.051) by .041 (1.244 or 1-1/4) will give you the distance the mandrel needs to travel to obtain the calculated expansion. Now knowing the distance the mandrel needs to travel, we are able to adjust the tool for the proper expansion. Loosen the set screw (18), then move the adjustment sleeve (19) by rotating it so you have an 1-1/4 distance between the mandrels shoulder and the mandrel thrust plate (21). Then re-secure the set screw (18). See the illustration below: 1-1/4
You are now ready to expand the first tube. Dip the expander in the bead tube lubricant and re-insert the expander into the tube. Expand the tube until the mandrels hub comes into contact with the mandrel thrust plate (21) and makes a few revolutions to iron out the bead. You will notice an increase in the drive motors RPM when the bead is finished. If the bead is not completely pressed up to the tube sheet, rotate the adjustment sleeve 11/2 revolutions and re expand the tube. If this does not pull the bead up to the sheet, then there may be too much tube projection. Reduce the projection on another tube by 1/32 and expand that tube. If the tubes you are roller bead expanding are just shy of being completely pressed to the tube sheet, then expand all the tubes with this adjustment setting. Increase the setting after all the tubes have been expanded. Re-expand only the tubes that the bead is not pressed against the tube sheet. Re-expanding tubes with the roller beading expander that have the bead completely pressed against the tube sheet will put extreme side load on the expander and reduce the expanders life. Remember to always dip and flush the expander into the bead lube to clean and cool the expander after each expansion. The expanders mandrel is equipped with a square on the front so the expander s drive motor can be used in reverse when expanding the internal tube sheet in the boiler.
Never attempt to expand the internal tube sheet by reaching through the combustion access hole. The Airetool beading expander generates great force and could cause injury to the operator. Always roll the internal tube sheet with an extension to drive the expander from the opposite end of the boiler.
Maintenance Inspect the mandrel and rolls on a continuous basis. Any time pitting or extreme wear is observed, replace these parts immediately to avoid damage to other expander components. After each shifts production completely dissemble the expander and wash all parts thoroughly with a solvent such as mineral sprits. To disassemble remove mandrel (23) from expander, remove retaining clip (1) and remove cage ring (2), remove retaining ring (3), pull roll retainer (4) from cage (8), loosen set screw (18) and unthread adjustment sleeve (19), remove retaining ring (22) and remove mandrel bearing (20) and mandrel thrust plate (21), remove retaining ring (17) and remove spring stop (16), spring (15) and retaining collar (14), loosen set screw (13), place nose of cage (8) in a vise and unthread thrust stem (12) from cage (8), (left hand thread) remove bearing (11) and thrust plate (9). After all parts have been thoroughly cleaned, apply grease to bearings (10), (11) and (20) and re-assemble the tool in reverse order.
AIRETOOL RBE SERIES ROLLER BEADING EXPANDER PARTS LIST

2" Item No. Description Description No. Material No. 1 Ret. Ring US 137 2900473 2 Cage Ring RBE 200 CR 2900371 3 Ret. Ring B 1158 RR 2993548 4 Roll Retainer RBE 200 2998686 5 Long Roll RBE 200 LR 2900368 6 Short Roll RBE 200 SR 2998705 7 Beading Roll RBE 200 156 2998665 8 Cage RBE 200 2998685 9 Thrust Plate RBE 200 TP 2998694 10 Plate Bearing RBE 200 PB 2900374 11 Thrust Bearing D 16 2973171 12 Thrust Stem RBE 200 TS 2998693 13 Brass Tip Set Screw 1/4 20 X 1/4 BT 8010931 14 Retaining Collar RBE 200 2998687 15 Spring RBE 200 SPR 2998689 16 Spring Stop RBE 200 SPS 2998688 17 Retaining Ring US 175 2900474 18 Set Screw 1/4 20 X 1/4 8006600 19 Adjustment Sleeve RBE 200 AS 2998690 20 Mandrel Bearing RBE 200 MTB 2998692 21 Mandrel Thrust Plate RBE 200 MTP 2998691 22 Ret Ring 5/8 2120600 23 Mandrel RBE 200 RM 2900497 24 Bead Lube Bead Lube 2900585 * One roll is sent as a spare. ** Not shown Tube OD 2-1/2" Description No. Material No. US 187 2900475 RBE 250 CR 2900372 B 1205 RR 2993659 RBE 250 2998696 RBE 250 LR 2900369 RBE 250 SR 2998706 RBE 250 156 2998666 RBE 250 2998695 RBE 250 TP 2998704 RBE 250 PB 2900375 D 20 2900381 RBE 250 TS 2998703 1/4 20 X 1/4 BT 8010931 RBE 250 2998697 RBE 250 SPR 2998699 RBE 250 SPS 2998698 US 212 2998762 1/4 20 X 1/4 8006600 RBE 250 AS 2998700 RBE 250 MTB 2998702 RBE 250 MTP 2998701 1 2001200 RBE 250 RM 2900498 Bead Lube 2900585 3 QTY Description No. Material No. US 225 2900476 1 RBE 300 CR 2900373 1 B 1276 RR 2993662 1 RBE 300 2998743 1 RBE 300 LR 2900370 4 RBE 300 SR 2998753 1 RBE 300 156 2998667 2* RBE 300 2998742 1 RBE 300 TP 2998751 1 RBE 300 PB 2900376 1 D-25 2900382 1 RBE 300 TS 2998750 1 1/4 20 X 1/4 BT 8010931 1 RBE 200 2998744 1 RBE 300 SPR 2998746 1 RBE 300 SPS 2998745 1 US 250 2900612 1 1/4 20 X 1/4 8006600 1 RBE 300 AS 2998747 1 RBE 300 MTB 2998749 1 RBE 300 MTP 2998748 1 B 1355 RR 2994211 1 RBE 300 RM 2900499 1 Bead Lube 2900585 1**
Notes:
AIRETOOL OPERATION 302 South Center Street Springfield, Ohio 45506

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OPERATING & SERVICE MANUAL # 90126-IM Rev.

READ SAFETY RECOMMENDATIONS BEFORE OPERATING THIS TOOL

AIRETOOL OPERATION 302 South Center Street Springfield, Ohio 45506

AIRETOOL RBE SERIES ROLLER BEADING EXPANDER PARTS LIST

AIRETOOL OPERATION 302 South Center Street Springfield, Ohio 45506

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