May Nong Unibell PDF

UNIBELL1 200 LE
(AUTOMATIC BELLING MACHINE)
READ THIS MANUAL

BEFORE USE
USER MANUAL EN
UM - 100431
05 - 2014 Rev. 01
TRANSLATION OF THE
UM_100431_01
ORIGINAL INSTRUCTIONS N. Machine

1507903
SICA S.p.A. reserves the right to prosecute, within the terms of the law, whosoever reproduces this document or discloses the contents
to third parties without prior written authorisation.
The descriptions and illustrations contained in this manual are not binding, although the basic characteristics of the type of machine
described are not subject to variation. The manufacturer reserves the right to make any modifications to the machine at any time in order
to improve the end product, with no commitment to updating the manual.
This manual must be kept for the entire lifetime of the machine in a location that is easily accessible to
all machine operators and maintenance personnel.
UNIBELL1 200 LE
(AUTOMATIC BELLING MACHINE)
SICA S.p.A.
Via Stroppata, 28 - 48011 Alfonsine (RA) ITALY
Tax Code and VAT number IT00084440395
Tel. ++39/0544/88711 - Fax ++39/0544/81340
UM_100431_01
Internet: http://www.sica-italy.com
e-mail: [email protected]
Customer Service
Tel. ++39/0544/88774 - Fax ++39/0544/88821
SUMMARY
1 GENERAL INFORMATION..........................5 3.6. Safety regulations
on the environmental impact.......................52
1.1. Purpose of the manual..................................5
3.7. Safety symbols description .........................53
1.2. Types of operator..........................................6
3.8. Signs position..............................................55
1.3. Manufacturer and machinery nameplate ......7
3.9. Description of safety devices ......................56
1.4. Technical service request procedures ..........8
3.10. Residual risks..............................................58
1.5. Terms and definitions ...................................8
All the functional units .................................58
1.6. Enclosed documentation ..............................9
3.11. Operating mode
2 TECHNICAL INFORMATION.....................11 due to emergency condition........................61
2.1. Machine general description.......................11 4 INFORMATION ON HANDLING AND

2.2. Constructive configuration of the machine..14 INSTALLATION OPERATIONS.................63
2.3. Optional accessories ..................................16 4.1. Recommendations for handling
2.4. Equipment supplied ....................................17 and installation ............................................63
Pipe heating equipment 4.2. Packing and unpacking...............................63
(Boosted air oven) ......................................17 4.3 Transport.....................................................64
2.5. Operating cycle...........................................18 4.4. Checking "Packing list" and
2.6. Belling cycle process ..................................19 state of packages........................................64
"Smooth mandrel" belling cycle ..................19 4.5. Handling and lifting .....................................65
2.7. Belling preparation cycle.............................20 List of dismantled parts ...............................66
2.8. "Smooth mandrel" belling cycle ..................23 4.6. Warehousing and storage procedures........67
2.9. Pipe unloading cycle...................................25 4.7. Characteristics of the installation
2.10. Electric devices...........................................27 environment ................................................67
Belling unit ..................................................28 4.8. Machine installation ....................................68
Bench unit...................................................30 4.9. Recommendations for utility connectionns .74
Infeed unit and pipe rolling unit...................32
Pipe heating unit .........................................33 4.10. Electrical connection ...................................74
2.11. Pneumatic devices......................................34 4.11. Pneumatic connection.................................76

Main air feed line ........................................34 4.12. Water connection ........................................76
Machine body .............................................36 4.13. Removing transport retention device s .......77
Bench unit...................................................38
4.14. Testing the machinery.................................77
2.12. Water devices .............................................40
2.13. Technical data ............................................42 5 5 INFORMATION ON ADJUSTMENTS .....79
2.14. Surrounding areas ......................................44 5.1. Recommendations for adjustments ............79
2.15. Noise level ..................................................45 5.2. Adjustment of chain (bench) .......................80
5.3. Drive chain adjustment
3 SAFETY INFORMATION ...........................47 (haul-off)......................................................81
3.1. General instructions....................................47 5.4. Chain adjustment
3.2. Handling and installation (motorised conveyor optional).....................82
regulations ..................................................48
6 ABOUT THE USE.......................................83
3.3. Regulations for operation and use..............49
6.1. Recommendations for use and operation ...83
3.4. Regulations for adjustment and
maintenance operations .............................50 6.2. Command description .................................84
3.5. Safety rules concerning 6.3. Activating and deactivating
electrical equipment....................................51 the pneumatic power supply .......................92
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6.4. Activating and deactivating 6.12.1Preparing for assembly
the water supply..........................................94 and disassembly .......................................124
6.5. Activating and deactivating the electrical 6.12.2Pipe clamp equipment assembly
power supply...............................................95 and disassembly .......................................125
Activating the machine in "0" mode ............95
6.13. Assembly of belling unit ............................126
Activating the machine in manual mode .....96
Activating the machine in manual mode 6.13.1Preparing for assembly
with guards excluded ..................................98 and disassembly .......................................126
Activating the machine in Automatic mode..100 Assembly and Disassembly of
Deactivating the electrical power supply Forming Carriage Equipment....................126
(machine off).............................................102 6.13.2Assembly and disassembly
6.6. Deactivating the energy sources of "Smooth mandrel" equipment ...............127
(machine disconnected)............................103 6.14. Checks during use ....................................128
6.7. Stop and restart mode ..............................104 6.15. Checking the thermal status
Arrest of the current procedure of the pipe to be belled..............................129
and restart.................................................104
Automatic stop due to alarm 6.16. Checking the thermal state
conditions and restart ...............................104 of the belled pipe.......................................130
Stop due to blackout and restart...............106 6.17. Checking socket dimensions ....................130
Stop due to end of production and restart 107
Normal stop (machine without pipes) .......108 7 INFORMATION ON MAINTENANCE.......131
Manual stop and restart 7.1. Recommendations for maintenance .........131
(machine with pipes).................................108
7.2. Routine maintenance ................................131
6.8. Format change..........................................109
7.3. Cleaning the machine ...............................134
6.9. Format change of pipe transfer unit..........110
7.4. Draining of air tank condensate ................135
Setting the length of pipe to be heated .....110
Bench positioning .....................................111 7.5. Draining exchanger condensate ...............136
Positioning of chips cleaning nozzles .......112 7.6. Chart of lubrication points .........................137
Setting the pressure (haul-off) ..................113 Bench - Pipe clamp - Belling unit ..............137
6.10. Format change of pipe heating unit ..........114 Conveyor - Pipe haul-off device................138
Setting the pressure (rotating clamp)........114 7.7. Lubricants table.........................................139
Setting the oven stroke .............................116
Setting the stiffness of the oven carriage 8 TROUBLESHOOTING .............................141
decelerator................................................117
8.1. Malfunctions..............................................141
Adjusting the position of the motorised
oven (optional) ..........................................118 9 INFORMATION ON SPARE PARTS........145
Adjusting the pipe edge cooler
of the boosted air oven .............................119 9.1. Recommendations for replacing parts ......145
Position of the oven gate 9.2. Replacing rollers and
(boosted version) ......................................121 pipe support wheels ..................................146
6.11. Assembling the pipe heating unit 9.3. Replacing the haul-off drive chain.............148
(boosted air oven).....................................122 9.4. Replacing haul-off wheels.........................149
6.11.1Preparing for assembly 9.5. Replacing the rotating clamp rollers..........150
and disassembly .......................................122
9.6. Machine decommissioning........................151
6.11.2Assembly and disassembly of pipe
9.7. Machine demolition ...................................151
heating equipment ....................................123
6.12. Assembly of the pipe clamp unit ...............124
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ANALYTICAL INDEX
A - Infeed unit and pipe rolling unit (32)
Accessories available upon request (16) - Pipe heating unit (33)
Activating and deactivating the electrical power supply (95) Electrical connection (74)
- Activating the machine in "0" mode (95) Electrical equipment, safety regulations (51)
- Activating the machine in manual mode (96) Enclosed documentation (9)
- Deactivating the electrical power supply (machine off) (102) Environmental impact, safety standards (52)
Activating and deactivating the electricity supply EP chamber equipment assembly and disassembly. (127)
- Activating the machine in automatic mode (100) Equipment supplied (17)
- Activating the machine in manual mode with guards - Pipe heating equipment (Boosted air oven) (17)
excluded (98) Exchanger draining condensate (136)
Activating and deactivating the pneumatic power supply (92) F
- Disabling of pneumatic power supply (92) Format change (109)
- Discharging the residual pneumatic power (92) Format change of pipe heating unit (114)
- Enabling of pneumatic power supply (92) - Adjusting the pipe edge cooler of the boosted air oven (119)
Activating and deactivating the water power supply - Setting the oven carriage stroke (116)
- Activating the water supply (94) - Setting the pressure (rotating clamp) (114)
- Deactivating the water supply (94) - Setting the stiffness of the oven carriage decelerator (117)
- Discharging the residual water energy (94) Format change of pipe transfer unit (110)
Activating and deactivating the water supply (94) - Bench positioning (111)
Adjusting the chain (bench) (80) - Positioning of chips cleaning nozzles (112)
Adjusting the position of the motorised oven (118) - Setting the length of pipe to be heated (110)
Adjustments and maintenance, regulations (50) - Setting the pressure (haul-off) (113)
Adjustments, recommendations (79) Format change of socket belling unit
Assembling and disassembling the equipment of the smooth - Position of the oven gate (boosted version) (121)
mandrel (machine with manual assembly) (127)
Assembling the belling unit, belling unit, Assembly (126) G
Assembling the pipe heating unit (boosted air oven) (122) General instructions (47)
Assembly and disassembly of the pipe heating equipment (123) H
Assembly of the pipe clamp unit (124)
Handling and installation regulations (48)
B Handling and installation, regulations (48)
Belling cycle process (19) Handling and lifting (65)
Belling preparation cycle (20) - List of dismantled parts (66)
Belling processes
I
- "MM segment in" belling cycle (20)
- "Smooth mandrel" belling cycle (19) Indications for utility connections (74)
C L
Chain adjustment (optional motorised conveyor) (82) Lifting and handling (65)
- List of dismantled parts (66)
Characteristics of the installation environment (67)
Chart of lubrication points (137) Lubricants table (139)
- Bench - Pipe clamp - Belling unit (137) Lubricants, table (139)
- Conveyor - Pipe haul-off device (138) M
Checking "Packing list" and state of packages (64) Machine general description (11)
Checking socket dimensions (130) Machine installation (68)
Checking the temperature of the belled pipe (130) Machine, cleaning (134)
Checking the temperature of the pipe to be belled (129) Machine, demolition (151)
Checks during use (128) Machine, disposal (151)
Cleaning the machine (134) Machine, general description (11)
Constructive configuration of the machine (14) Machine, installation (68)
Controls, description (84) Machine, Manufacturer nameplate (7)
D Machine, testing (77)
Malfunctions (141)
Deactivating the energy sources (machine disconnected) (103) Manual, purpose (5)
Definitions and terms (8) Manufacturer and machine, identification (7)
Description of controls (84) Manufacturer and machinery nameplate (7)
Description of safety devices (56)
Draining of air tank condensate (135) N
Drive chain adjustment (haul-off) (81) Noise level (45)
E O
Electric devices (27) Operating cycle (18)
- Belling unit (28) Operating mode due to emergency conditions (61)
- Bench unit (30) Operation and use, recommendations (83)
Operation and use, regulations (49)
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Operation, faults (141) U
Operator, types (6) Utility connections, recommendations (74)
P W
Packing and unpacking (63) Warehousing and storage procedures (67)
Pipe clamp assembly and disassembly (125) Water connections (76)
Pipe clamp unit, Assembly (124) Water devices (40)
Pipe clamp, equipment assembly and disassembly (125)
Pipe heating unit, Assembly (122)
Pipe heating, assembly and disassembly of the equipment (123)
Pipe unloading cycle (25)
Pneumatic connection (76)
Pneumatic devices (34)
- Bench unit (38)
- Machine body (36)
- Main air power line (34)
Preparing for assembly and disassembly (122), (124), (126)
Purpose of the manual (5)
R
Recommendations for adjustments (79)
Recommendations for handling and installation (63)
Recommendations for maintenance (131)
Recommendations for replacing parts (145)
Recommendations for use and operation (83)
Recommendations, maintenance (131)
Regulations for adjustment and maintenance operations (50)
Regulations for operations and use (49)
Removing transport retainers (77)
Replacing haul-off wheels (149)
Replacing parts, recommendations (145)
Replacing the haul-off drive chain (148)
Replacing the rollers and pipe support wheels (146)
Replacing the rotating clamp rollers (150)
Residual risks (58)
- All the functional units (58)
Routine Maintenance (131)
S
Safety devices, description (56)
Safety regulations on the environmental impact (52)
Safety rules concerning electrical equipment (51)
Safety signs description (53)
Safety signs, description (53)
Scrapping the machine (151)
Signs position (55)
Signs, position (55)
"Smooth mandrel" belling cycle (23)
Stop and restart mode
- Automatic stop due to alarm conditions and restart (104)
- Stop due to blackout and restart (106)
Stop/restart mode (104)
- Arrest due to end of production and restart (107)
- Arrest of the current procedure and restart (104)
- Manual stop and restart (machine with pipes) (108)
- Normal stop (machine without pipes) (108)
Surrounding areas (44)
T
Taking the machine out of service (151)
Technical data (42)
Technical service request procedures (8)
Technical service request, procedures (8)
Technical service, request procedures (8)
Terms and definitions (8)
Testing the machinery (77)
Transport (64)
Transport retainers, removal (77)
Types of operator (6)
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Chapter 1
GENERAL INFORMATION 1
1.1. PURPOSE OF THE MANUAL

– The manual herein, part and parcel with the machinery, has been pre-
pared by the manufacturer with the purpose to supply the necessary in-
formation to the persons authorised to operate the machinery during its
useful life.
– As well as adopting an appropriate utilisation technique, the recipients
of the information must read and strictly apply it.
– This manual was originally written in Italian and has been translated in
compliance with legislative requisites and for commercial purposes.
A little time dedicated to the study of this information, will permit the user
to avoid health and safety risks to personnel and economic loss.
– The translation in the language of the country of use, supplied by the
manufacturer, its representative or whoever brings the machine to such
linguistic area, must be carried out from the "ORIGINAL INSTRUC-
TIONS" and must display the phrase "TRANSLATION OF THE ORIGI-
NAL INSTRUCTIONS".
– In the event that the manual herein contains additional information con-
cerning the fittings of the machinery, said information does not interfere
with the reading of the manual.
– Keep this manual for the entire duration of the machine's useful life in a
well known and easy to access place, available for reference any time the
need should arise.
– The manufacturer reserves the right to make modifications with no ob-
ligation to supply a prior notification.
– To highlight some parts of the text that are important or to indicate some
important specifications, some symbols have been adopted whose
meanings are explained below.
Danger - Warning
Indicates situations of severe danger which, if neglected, may put
personal health and safety at serious risk.
Caution - Note
Indicates that appropriate measures are necessary in order to pre-
vent risk to personal health and safety and damage to property.
Important
Indicates technical information of particular importance which must
not be overlooked.
UM_100431_01
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Chapter 1
GENERAL INFORMATION
1.2. TYPES OF OPERATOR

Below is a list of the types of operator responsible for the installation, run-
ning and maintenance of the machine.
Danger - Warning
Each operator should only carry out the duties for the category he
belongs to. For all the work outside his area of competence he must
call upon the specific operators for that area in order to prevent put-
ting himself and other operators working with the machine at risk.
Installer: A technician, chosen and authorised by the manufactur-
er with the necessary competence and information to carry out the
assembly and installation operations correctly. If necessary, this techni-
cian will also train and instruct the line manager.
Testing technician: A technician, chosen and authorised by the
manufacturer with the necessary competence and information to
carry out the inspection and commissioning of the machine or plant cor-
rectly and without any danger. The technician will also have to, if neces-
sary, train and educate the plant manager.
General trained operator: A technician appointed and authorised by the
manufacturer, trained to carry out general supervisory operations on the
plant and working on the machine's operating parameters (adjustment of
these parameters, the starting and stopping of the automatic cycle). The
operator must report all machine malfunctions noted to the line manager.
The operator must not carry out any operation that, according to the man-
ual, is to be performed by a qualified technician. He should not carry out
any operations that require access to the inside of the machine.
Technician who is an expert in the mechanical field: A techni-
cian with proven experience in the mechanical field, authorised by
the line manager to work on plastic pipe extrusion lines, including belling
machines. He will have proof that he has taken training courses held by
the manufacturer specifically for running and managing these machines.
He should have all the information needed for format change operations,
and for running and maintaining the machine. He should not perform any
operation without prior authorisation from the line manager.
Technician who is an expert in the electrical field: A technician
with proven experience in the electrical field, authorised by the line
manager to work on plastic pipe extrusion lines, including belling ma-
chines. He will have proof that he has taken training courses held by the
manufacturer specifically for running and managing these machines. He
should have all the information needed for running the machine. He
should be capable of working around voltage inside the electrical cabi-
nets and electrical boxes. He must not carry out any format change op-
eration that is the specific area of competence of the technician who is
skilled in the mechanical field. He should not carry out any operation with-
out prior authorisation from the line manager.
Line manager: A technician with proven experience in managing
UM_100431_01
extrusion lines, including belling machines. He is responsible for

selecting and training personnel employed in the operation of the produc-
tion line in which the machine is installed. The line manager holds and is
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Chapter 1
GENERAL INFORMATION
responsible for the keys for restricted machine controls. The line manag-
er is also responsible for authorising and supervising all work necessary
on the machine and ensuring that it is conducted in safety.
1.3. MANUFACTURER AND MACHINERY

NAMEPLATE
The identification plate illustrated is affixed directly onto the machine. The
plate contains all identification details and indications necessary for safe
operation.
A B
D
E
F
G
H
N M L
A – Manufacturer nameplate
B – Machine serial number
C – Space left for CE conformity mark
D – Year of manufacture
E – Mains electric intensity
F – Power supply voltage
G – Rated electrical power
H – Mains frequency
L – Machine weight
M – Number of phases
N – Machine model
UM_100431_01
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Chapter 1
GENERAL INFORMATION
1.4. TECHNICAL SERVICE REQUEST

PROCEDURES
For any requirement, please contact the manufacturer’s Support Service.
For any technical service request, indicate the data shown on the identi-
fication plate, the approximate number of hours the machine has worked,
and the type of malfunction.
1.5. TERMS AND DEFINITIONS

A description is given for some terms used in this manual, so they can be
more easily understood.
– Assembly axis: the axis of the pneumatic cylinder that loads the ring onto
the flange.
– Belling (Belling cycle): hot deformation of a plastic pipe by which the end
of the pipe is widened and shaped with an appropriate tool.
– Belling position: position of the pipe on the pipe arrival conveyor before
being sent to the machining devices (oven/s, belling cycle).
– Blowing: pressurized air that pushes on the inner wall of the warmed pipe
and shapes the gasket seat and/or socket.
– E.P. (external pressure): high-pressure air that pushes against the outer
wall of the warmed pipe and shapes the socket against the mandrel.
– E.P. belling chamber: volume formed by the machined pipe and machine
parts in which the socket is made by means of the E.P.
– Equipment: part of the machine that must be replaced on the basis of the
characteristics of the new machining operation to be performed (pipe diam-
eter, socket length, etc.).
– Format change: set of operations needed to adapt the machine to a new
machining mode depending on the pipe characteristics (equipment assem-
bly, adjustments, etc.).
– Inflation: pressurized air that pushes against the inner wall of the warmed
pipe by means of an expandable rubber ring and shapes the gasket seat
and/or socket.
– Loading axis: the axis that inserts the ring. It coincides with the belling ax-
is.
– Long pipe: pipe machined when already released from the previous ma-
chine (saw) of a length superior to 3 metres.
– Lubrication axis: the rotation axis of the ring lubrication tool.
– Machine left: machine version in which the operator, with his back facing
the extruder, sees the pipe coming from the left side of the machine and
moving from left to right.
– Machine right: machine version in which the operator, with his back facing
the extruder, sees the pipe coming from the right side of the machine and
moving from right to left.
– Pipe length: length of the pipe without the section to be belled.
UM_100431_01
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Chapter 1
GENERAL INFORMATION
– Pipe stand-by position: the position that the parts of the machine assume
when the machine is in automatic operation at the end of the positioning
phase. In this position the moving parts are ready to receive a pipe to be ma-
chined.
– Position: final position to be reached.
– Pre-position: intermediate position between position "0" (mechanical limit
stop) and the final position (Position); it is set to reduce unnecessary move-
ments and speed up the machining cycle.
– Pressing: shortening of the machined pipe due to the shaping of the gas-
ket seat. It can vary from 0 mm (in case of a smooth socket) to 80 mm and
over for large diameter pipes and socket with gasket seat.
– Routine maintenance: a series of operations necessary to maintain cor-
rect machine functionality and efficiency. These operations are normally
scheduled by the manufacturer, which also defines the skills necessary and
procedures.
– Short pipe: pipe machined when already released from the previous ma-
chine (saw) of a length equal or inferior to 3 meters.
– Socket conic section: initial section of the socket whose conical shape al-
lows it to fit with a non-deformed cylindrical pipe.
– Socket: shaped at the end of the pipe obtained after belling.
– T.M.: abbreviation for "Mechanical Mandrel".
– Unscheduled maintenance: a series of operations necessary to maintain
correct machine functionality and efficiency. These operations are not
scheduled by the manufacturer and must be carried out by the maintenance
technician.
– Zero line (machine zero): Ideal fixed straight line compared to the ma-
chine that separates the pipe section to be belled from the rest of the pipe.
1.6. ENCLOSED DOCUMENTATION

In addition to this manual the client receives the specified documentation.
– Terminal "Operating Guide".
– Equipment assembly manual.
– Oven user manual.
– User Manual for the belling equipment lifting device.
– Electrical diagram.
– Pneumatic diagram.
– Water system diagram.
UM_100431_01
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Chapter 1
GENERAL INFORMATION
UM_100431_01
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Chapter 2
TECHNICAL INFORMATION 2
2.1. MACHINE GENERAL DESCRIPTION
Pipe unloading area
Belling and socket cooling area

Pipe heating area
Pipe entrance area
The automatic belling machine of the UNIBELL1 200 LE series are ma-
chines designed and constructed to carry out the belling of rigid PVC-U/
ABS pipes with pre-established dimensions (diameter, thickness,
length).
The models in this range include specific systems for heating, belling and
cooling the pipe, as described below.
UNIBELL1 200 LE
Machine for creating a smooth socket. The pipe is heated in a boosted
thermoregulated air oven.
The cooling of the socket occurs as a result of pre-cooled ventilated air
using a heat exchanger.
– The heat-forming process is described, according to the type of socket,

in paragraph 2.6. - "Belling cycle process".
For every type of belling, specific equipment and accessories are re-
quired (supplied directly by the manufacturer), described in paragraph
2.4. - "Equipment supplied".
UM_100431_01
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Chapter 2
TECHNICAL INFORMATION
– The machine can be programmed to bell pipes of various lengths but

with the same size characteristics (diameter and thickness), regardless
of the pipe extrusion speed.
If the pipe extrusion speed is too high, the machine will reject the pipes it
cannot process (but without interrupting the operating cycle).
For information about the workable pipe size characteristics, refer to par-
agraph 2.13. - "Technical data".
– The machine is equipped with an operating terminal for programming
the working parameters, to save process data and control the operation
status, and with a control board to manage operation support functions.
– The machine should be installed in an extrusion line.
The installation of the machine must be predefined with an overall pro-
ject, to find the most suitable solution from those available.
– Based on what arises from the installation project, the machine can be
realised in a "RIGHT" (standard) version or "LEFT" (optional) version and
it can be equipped with specific accessories to satisfy the production
needs.
The illustrations and descriptions given in this manual refer to the
RIGHT VERSION of the machine.
UM_100431_01
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Chapter 2
– In the installation project, evaluate at least the conditions listed and con-
sider the protection devices and systems to be installed in order to elim-
inate risks and to maintain an adequate level of safety.
1 – Lay-out and operational functionality of the extrusion line in which the
machine is to be installed.
2 – Disposition of other production lines or machines in the production ar-
ea, adjacent to the extrusion line in which the machine is to be installed.
3 – Surrounding areas and internal architecture of the factory.
– The illustration shows an example of an installation lay-out of the ma-
chine in an extrusion line.
Extrusion axis Belling machine Planetary

saw
Conveyor belt
Palletiser
– Upon completion of machine installation, before starting extrusion line

production activities, the installation manager must perform a risk evalu-
ation in order to establish whether the solutions adopted respect the es-
sential safety requirements.
– For the production phases of the machine, only one adequately trained
operator is required who must be capable of checking the correct opera-
tion of the machine and the line on which it is installed.
The operator must possess cultural and behavioural characteristics suit-
ed for the duties entrusted him or her. For more details on the character-
istics of the operator see paragraph 1.5. - "Terms and Definitions".
UM_100431_01
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Chapter 2
2.2. CONSTRUCTIVE CONFIGURATION OF THE

MACHINE
The main units of the standard machine are illustrated and described be-
low.
A – Pipe transfer unit
1 – Pipe infeed conveyor: consists of a "V" chute to support the pipes
arriving from the machine upstream, and guide them towards the haul-off
device.
2 – Pipe haul-off device: hauls the pipe arriving from the feed line, and
stops it in the belling position.
The device is equipped with an air blower to remove the chips from the
end of the pipe to be heated.
3 – Pipe transfer bench: supports the pipes during machining, moves
them from one workstation to the next and then unloads them at the end
of the machining process.
The bench can be positioned at different heights according to the pipe di-
ameter, in order to align the pipe axis with the axis of the belling parts.
B – Pipe heating unit
1 – Pipe rolling clamp: rotates the pipe being heated alternately clock-
wise and counter-clockwise in the oven, so the heating is uniform.
2 – Oven: with boosted, thermoregulated air, is positioned on an inde-
pendent carriage and heats the end of the pipe to be belled.
C – Belling unit
1 – Pipe clamp: holds the pipe in place during the belling phase and, via
the front semi-flanges united with the clamps, ensures the E.P. chamber
is sealed during this phase:
2 – Forming carriage: supports and moves the belling cycle equipment
(mandrel and diffuser). For more information, see 2.4. - "Equipment sup-
plied".
3 – Mandrel: it is inserted in the pipe, to calibrate the socket.
4 – Cooler: the cooler conveys air onto the pipe to stabilise the socket
and cool it.
D – Electrical panel: contains the electric power and command devices
for the machine. Some controls can be on the flyboard (D1), if present.
For further information, see 6.2. - "Description of controls".
E – Pneumatic check point: contains the check and adjustment devices
for the machine's pneumatic operations. For more information, see para-
graph 2.11. - "Pneumatic devices".
UM_100431_01
- 14 -
Chapter 2
AIR E
D
B1
B2
D1
C1
C4
C3
A3
C2
A2
A3
A1
UM_100431_01
- 15 -
Chapter 2
2.3. ACCESSORIES AVAILABLE UPON REQUEST

To increase the performance level and versatility of the machine, the fol-
lowing optional accessories are available upon request from the manu-
facturer.
– Support feet boosters: used to increase the height of the machine's
working axis.
– Pipe infeed conveyor unit (motorised): used to improve machine pro-
ductivity when processing short pipes only, or alternated long and short
pipes.
The unit is equipped with a series of rollers activated by an electric motor.
These rollers transfer the pipe at a speed greater than the extrusion
speed, so idle time is reduced (they anticipate the pieces of short pipe be-
neath the haul-off, and store other incoming pipes).
– Heating cycle stroke air flow limit unit: used for heating pipes with a
diameter less than 2 mm. The carriage oven carries out an initial partial
run and then a complete one, to provide differentiated heating between
the first part of the pipe (hotter) and the second part (less hot).
– Pipe side feeding: used when, for production line needs, it is prefera-
ble to feed the machine with pipes coming from the side of the bench.
UM_100431_01
- 16 -
Chapter 2
2.4. EQUIPMENT SUPPLIED

The equipment is available in different sizes depending on pipe diameter
and on the type of machining to be carried out. The equipment supplied
together with the machine is agreed upon with the client at the time of or-
der.
For all queries, contact the manufacturer's Support Service.
Pipe heating equipment (Boosted air oven)
A – External closure flange.
B – Internal clamping washer.
C – Pipe edge cooler.
D – Internal diffuser tube. a D C A B
E – Gate.
Important
Components (A-B-D) are availa-
ble in different measurements
depending on the pipe diameter.
Using the pins (a) the position of
the air flow limit gate to be mod-
ified, and therefore the distribu- a E
tion of heat over the inside and
outside of the pipe (see sec. 6.11
"Assembling the pipe heating
unit (boosted air oven)").
The component (C) changes for groups of diameters.
On every piece of equipment is stamped the pipe diameter for which
it is intended.
Equipment for belling smooth sockets

A – Mandrel-holder shaft
B – Mandrel
C – Pipe clamp
D – Reduction element for pipe clamp
D C
D C
A
B
UM_100431_01
- 17 -
Chapter 2
2.5. OPERATING CYCLE
Pipe infeed phase
OPTIONAL
Belling preparation cycle Pipe unloading cycle
"Smooth mandrel"
belling
cycle
Pipe unloading
UM_100431_01
- 18 -
Chapter 2
2.6. BELLING CYCLE PROCESS

Below is a description of the "Smooth mandrel" belling process.
"Smooth mandrel" belling cycle
Belling cycle process of the smooth
socket, achieved with smooth met-
al mandrel. The correct belling cy-
cle of the socket is carried out
through the calibration action on
the mandrel and the contempora-
neous cooling with pre-cooled ven-
tilated air.
UM_100431_01
- 19 -
Chapter 2
2.7. BELLING PREPARATION CYCLE

1 – The pipe (A) is transferred to
the conveyor (B).
B A
2 – The photocell (W) detects the

presence of the pipe. Once the set
delay time has elapsed, the haul-off
device (C) is activated.
When the photocell (W) no longer
detects the pipe, a jet of air is acti-
vated to remove chips from the
area of the pipe to be heated.
The haul-off device (C) remains ac- C
tive for the time needed to transfer
the pipe (A) to the heating position. Z
A
Then it stops and returns to the
W
pipe stand-by position.
Useful information for ma-
chines with motorised pipe in-
feed conveyor only.
The roller unit is always enabled.
When the photocell (Z) detects the
presence of a new pipe while the
previous one is still in the haul-off area, the roller unit stops. It starts again
as soon as the pipe is transferred to the heating position.
If the arrival of another pipe pushes the one on the roller unit as far as the
photocell (W), the "discard positioned pipe" phase will be activated.
UM_100431_01
- 20 -
Chapter 2
3 – Beam 1 lifts the pipe and places

it in front of the oven. It then moves
Oven
back to its standby position.
Pipe
Beam 1
4 – The rolling clamp (D) lowers

and controls the rotation of the pipe
alternately clockwise and counter- (D)
clockwise.
Oven
Pipe
5 – Oven advances, wrapping the

part of the pipe to be heated.
Pipe Oven 1
UM_100431_01
- 21 -
Chapter 2
6 – Once the pipe heating has fin-

ished, the rolling clamp (D) is deac-
tivated and lifts up and the oven D
draws back.
Oven
Pipe

it in front of the belling station. It
then moves back to its standby po-
sition.
Pipe
Beam 2
8 – The clamp (F) locks the pipe in

place.
The pipe is ready for one of the
(F)
belling cycles.
Important
The "Pipes Unloading" cycle can
be started if the pipes do not
need to be machined (heating
and belling) and if you do not
wish to stop the production line.
Pipe
UM_100431_01
- 22 -
Chapter 2
2.8. "SMOOTH MANDREL" BELLING CYCLE

The description of the various phases of the belling cycle specifies the
parameters (times and positions), with reference to the relative field/zone
numbers given on the pages of the operating terminal.
1 – The forming carriage (G) moves

forward to the set position ("Car-
riage positions" field, zone "74").
The mandrel (H) is completely in-
side the pipe (T).
2 – The "COOLING" timer starts

("cooling time" field, zone "60").
Pre-cooled ventilated air is sent
hrough the diffuser (A), which cools
and stabilises the socket. A
UM_100431_01
- 23 -
Chapter 2
3 – Once the time of the "COOL-

ING" timer has passed, the car-
riage (G) draws back returning to
the "pipe stand-by" position.
4 – The clamp (F) opens.

The pipe (T) is unloaded from the
machine when the next pipe is
(F)
transferred to the belling station.
(T)
UM_100431_01
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Chapter 2
2.9. PIPE UNLOADING CYCLE

1 – The pipe (A) is transferred to
the conveyor (B).
B A
2 – The photocell (W) detects the

presence of the pipe. Once the set
delay time has elapsed, the haul-off
device (C) is activated.
When the photocell (W) no longer
detects the pipe, a jet of air is acti-
vated to remove chips from the
area of the pipe to be heated.
The haul-off device (C) remains ac- C
tive for the time needed to transfer
the pipe (A) to the heating position. Z
A
Then it stops and returns to the
W
pipe stand-by position.
Useful information for ma-
chines with motorised pipe
infeed conveyor only.
The roller unit is always enabled.
When the photocell (Z) detects the
presence of a new pipe while the
previous one is still in the haul-off area, the roller unit stops. It starts again
as soon as the pipe is transferred to the heating position.
If the arrival of another pipe pushes the one on the roller unit as far as the
photocell (W), the "discard positioned pipe" phase will be activated.
UM_100431_01
- 25 -
Chapter 2

it in front of the oven. It then moves Oven
back to its standby position.
Pipe
Beam 1

it in front of the belling station. It
then moves back to its standby po-
sition.
Pipe
Beam 2
5 – The pipe is unloaded by the ma-

chine when the next pipe is trans-
ferred to the belling station.
UM_100431_01
- 26 -
Chapter 2
2.10. ELECTRIC DEVICES

To facilitate search and consultation activities, the electric devices have
been subdivided into several tables according to the listed operating ar-
eas of the machine.
– Belling unit
– Bench unit
– Infeed and pipe rolling unit
– Pipe heating unit
The position of some devices shown may not match exactly the actual
configuration of the machine.
To identify the device required, the technician should refer to the code
found on the device itself and on the electrical diagram.
Important
For more details, see the electrical diagram.
UM_100431_01
- 27 -
Chapter 2
Belling unit
10
9
4
1
Table 2.2: Electric devices

Ref. Description Function
1 Photocell detects the presence of the pipe in the belling unit.
detects the "closed" position of the protective mobile guard in the

2 Micro-switch maintenance zone, to enable the start of the operating cycle in
"automatic" mode.
3 Sensor detects the "closed" position of the pipe clamp.
4 Sensor detects the "open" position of the pipe clamp.

UM_100431_01
5 Sensor detects the "back" position of the forming carriage.
6 Sensor detects the "forward" position of the forming carriage.
- 28 -
Chapter 2

detects the "closed" position of the pipe clamp protective sliding guard, to
7 Micro-switch
enable the start of the operating cycle in "automatic" mode.
detects the "closed" position of the belling cycle protective guard to

8 Micro-switch
enable the start of the operating cycle in "automatic" mode.
9 Motor enables the movement of the forming carriage.
10 Motor operates the fan

UM_100431_01
- 29 -
Chapter 2
Bench unit
3
9
2
8
7
11
6 4 10
5
12
235180017-00
UM_100431_01
- 30 -
Chapter 2

1 Electric motor starts the device for adjusting the bench height.
2 Micro-switch detects the "high" position of the bench.
3 Micro-switch detects the "low" position of the bench.
4 Sensor detects the "backward" position of beam 1 of the bench.
5 Sensor detects the "forward" position of beam 1 of the bench.
6 Sensor detects the "backward" position of beam 2 of the bench.
7 Sensor detects the "forward" position of beam 2 of the bench.
8 Sensor detects the "lowered" position of beam 1 of the bench.
9 Sensor detects the "raised" position of beam 1 of the bench.
10 Sensor detects the "lowered" position of beam 2 of the bench.
11 Sensor detects the "raised" position of beam 2 of the bench.
for versions with pipe side infeed, it detects the "lowered" position of the
12 Sensor (if present)
infeed pipe stop levers.
UM_100431_01
- 31 -
Chapter 2
Infeed unit and pipe rolling unit
6 7 4
8
2

detects the movement of the pipe, after the activation of the pipe haul-off
1 Encoder
device, to stop it in the "belling" position.
2 Electric motor activates the pipe entry haul-off device.
3 Electric motor activates the rollers of the oven rolling clamp.
4 Electric motor (if present) activates the pipe feed roller unit.
detects the presence of the pipe on the bench and, together with the
photocell (7), deactivates and re-activates the pipe haul-off device to
5 Photocell
manage the "pipe not cut detection" function, which stops the machine in
the "PIPE NOT CUT" alarm condition if necessary.
6 Photocell (if present) detects the ends of the pipe, to start and stop the motorised conveyor.
detects the presence of the pipe arriving from the feeder line and hence
determining the activation of the haul-off device. When it no longer
7 Photocell detects the pipe dragged by the haul-off device, this determines the pipe
positioning start and the activation of the chip removal blower, which
remains active for the entire duration of the positioning operation.
UM_100431_01
- 32 -
Chapter 2

Photocell (integrated into

for versions with pipe infeed from the side, it detects the presence of the
8 the pipe infeed chute) (if
infeed pipe to activate the pipe haul-off device.
present)
Pipe heating unit
2
3
4
2

1 Sensor detects the "backward" position of the oven carriage.
2 Electric motor activates the oven fan.
3 Thermocouple measures the oven temperature.
4 Gear motor (if present) activates the oven positioning (if present)
5 Linear encoder (if present) detects the position of the heating cycle shutter unit (if present).
UM_100431_01
- 33 -
Chapter 2
2.11. PNEUMATIC DEVICES

To facilitate search and consultation activities, the pneumatic devices
have been subdivided into several tables according to the listed operat-
ing areas of the machine.
– Main air power line
– Machine body
– Bench unit
To identify the function of the solenoid valves, the technician should refer
to the code found on the device itself and also consult the relative dia-
grams (electric, pneumatic, etc.).
Important
For more details, see the pneumatic diagram.
Main air power line
5b
6
5a
2
3
1 4
UM_100431_01
- 34 -
Chapter 2
Table 2.6: Pneumatic devices

1 Tap used to enable the main pneumatic power supply.
2 Single-acting valve prevents the tank from being emptied if the delivery pressure drops.
accumulates the air reserve necessary to meet the consumption peaks of

3 Air tank (mains pressure)
some cycle phases.
4 Tap used to drain the condensate from the tank using mains pressure.
Inlet air treatment unit of

5 see "Maintenance sheet MR89".
the feed line
used to turn the pneumatic power supply of the line air on and off.
5a Tap Important
In the "CLOSED" position, the tap discharges the residual pressure
from the main pneumatic circuit.
Pressure regulator with

5b used to adjust the pressure and hold back the impurities of the line air.
filter and pressure gauge
detects the value of the operating pressure and indicates when it falls
below the set value.
6 Pressure sensor Important

The instrument is suitably adjusted by the manufacturer to a pres-
sure of 4.5 bar and must not be tampered with. If necessary, contact
the Support Service of the manufacturer.
rapidly discharges the air pressure of the machine drives in case of

emergency stop or electrical black outs.
Caution - Note
7 Cut-off solenoid valve
After the solenoid valve (7) has been deactivated, the counter-pres-
sure of the haul-off device and the rolling clamp remain supplied
with pneumatic energy. For more details, see the pneumatic dia-
gram.
UM_100431_01
- 35 -
Chapter 2
Machine body
2 1 12 10
16
7
8 11 9
13
17
18 20
3 4 5 6
14
15
18
19

1 Solenoid valve activates the air blowing valve to clean the pipe.
used to switch on/off the power supply to the air blower device for
2 Tap
removing chips.
3 Solenoid valve operates the cylinder of the cooling air opening/closing saddle.
4 Solenoid valve activates the actuator for the oven rolling clamp.
5 Solenoid valve activates the actuator for the pipe haul-off device.
UM_100431_01
6 Solenoid valve activates the actuator of the oven carriage.
- 36 -
Chapter 2

adjusts the operating counter-pressure of the haul-off device.
Important
7 Pressure regulator
The instrument is suitably adjusted by the manufacturer, and must
not be tampered with. If necessary, contact the Support Service of
the manufacturer.
regulates the operating back pressure of the oven rolling clamp.
Important
8 Pressure regulator
The instrument is suitably adjusted by the manufacturer, and must
not be tampered with. If necessary, contact the Support Service of
the manufacturer.
9 Pressure regulator adjusts the operating pressure of the haul-off device.
detects the operating pressure of the haul-off device, adjusted by means

10 Pressure gauge
of the regulator (9).
11 Pressure regulator adjusts the operating pressure of the pipe rolling clamp.
detects the operating pressure of the oven rolling clamp, adjusted by

12 Pressure gauge
means of the regulator (11).
13 Pneumatic cylinder (*) activates the ascent/descent of the oven rolling clamp.
14 Pneumatic cylinder (*) activates the oven carriage.
15 Pneumatic cylinder operates the cylinder of the cooling air opening/closing saddle.
16 Pneumatic cylinder activates the ascent/descent of the pipe haul-off device.
17 Solenoid valve activates the actuator of the pipe clamp.
18 Pneumatic cylinder enables the opening and closing of the pipe clamp.
Check valve
19 blocks the forward/backward movement of the oven carriage.
(if present)
Solenoid valve
20 operates the check valve (19).
(if present)
(*) The pneumatic cylinder is equipped with the tools (flow regulators) to
adjust the speed of movement.
The instrument has been suitably adjusted by the manufacturer, and
must not be tampered with. If necessary, contact the Support Service
of the manufacturer.
UM_100431_01
- 37 -
Chapter 2
Bench unit
6 7 8 9 10
4
2
235180020-00
UM_100431_01
- 38 -
Chapter 2

1 Pneumatic cylinder (*) activates the movement of beam 1 of the bench.
2 Pneumatic cylinder (*) activates the movement of beam 2 of the bench.
3 Pneumatic cylinder (*) activates the ascent/descent of beam 1 of the bench.
4 Pneumatic cylinder (*) activates the ascent/descent of beam 2 of the bench.
Pneumatic cylinder (*) (if for versions with pipe infeed from the side, it activates the ascent/descent
5
present) of the pipe stop levers.
for versions with pipe side infeed, it activates the ascent/descent actuator
6 Solenoid valve (if present)
of the pipe stop levers.
7 Solenoid valve activates the actuator for shifting beam 1 of the bench.
8 Solenoid valve activates the actuator for shifting beam 2 of the bench.
9 Solenoid valve activates the actuator for raising/lowering beam 1 of the bench.
10 Solenoid valve activates the actuator for raising/lowering beam 2 of the bench.
(*) The pneumatic cylinder is equipped with the tools (flow regulators) to
adjust the speed of movement.
The instrument has been suitably adjusted by the manufacturer, and
must not be tampered with. If necessary, contact the Support Service
of the manufacturer.
UM_100431_01
- 39 -
Chapter 2
2.12. WATER DEVICES

The illustration indicates the position of the devices.
Important
For more information, refer to the water system diagram.
A A
7
C C
10 11
B
B
1 2 3 4 6
9
UM_100431_01
- 40 -
Chapter 2
Table 2.12: Water devices

1 Tap used to open and close the mains water supply.
2 Tap used to open and close the mains water outlet.
3 Tap used to open and closed the cooled water supply.
4 Tap used to open and close the cooled water drainage.
cools the air used for socket cooling by means of heat exchange with the
5 Heat exchanger
water.
opens and closes the outlet of the condensate collection tank under the
6 Tap
heat exchanger.
opens the water supply of the mandrel cooling circuit or the water
discharge of the mandrel.
7 Tap To open the mandrel cooling circuit, turn the taps (7) and (8) to (A). To
open the mandrel draining circuit, turn the taps (7) and (8) to (B). To close
the taps (7) and (8) turn them to (C).
opens the water supply return of the mandrel cooling circuit or the
opening of the air and the water discharge of the mandrel.
8 Tap To open the mandrel cooling circuit, turn the taps (7) and (8) to (A). To
open the mandrel draining circuit, turn the taps (7) and (8) to (B). To close
the taps (7) and (8) turn them to (C).
discharges the pressure from the water system for pipe edge cooling,
Maximum pressure valve
9 when it reaches the set value (only with thermoregulated air-ventilated
pressure
oven).
enables and disables the water supply to the oven cooler (only with
10 Tap
thermoregulated, air-ventilated oven).
enables and disables the water flowback from the oven cooler (only with
11 Tap
thermoregulated, air-ventilated oven).
UM_100431_01
- 41 -
Chapter 2
2.13. TECHNICAL DATA
H
H2
W
?
Table 2.14: Machine technical data
Unit of
Description meas- UNIBELL1 200 LE
urement
Dimensions
Length (L) mm 8626
Width (W) mm 2134
Height (H) mm 2022
min 1000
Extrusion axis height (H2) mm
Max 1100
Weight kg 3100
Technical specifications
Installed power (50 Hz) kW 18
Voltage V 220-380
Power supply frequency Hz 50-60
Auxiliary circuits voltage Vdc 24
Pneumatic system operating pressure bar 6

UM_100431_01
Air consumption (p=6 bar,T=293K) l/min 800
Water consumption m³/h 0.4
- 42 -
Chapter 2
Table 2.14: Machine technical data

Unit of
Description meas- UNIBELL1 200 LE
urement
Compressed air supply
Maximum pressure bar 10
Filter fineness (particle size). μm Max 40
Filter fineness (particle density). mg/m³ Max 10
Humidity (dew point). °C Max 3
Lubrication mg/m³ Max 5
Water supply
Temperature °C 5 - 15
Maximum pressure bar 3
pH 6.5 - 7.5
Degree of filtration μm 10
Ambient conditions
Maximum altitude (a.s.l.) m 1000
Relative humidity (measured at a 50% (40°C)

Rhu
temperature between 40°C and 20°C) 90% (20°C)
Luminosity lux 250 - 650
Ambient operating temperature °C 5 - 40
Transport and storage temperature °C -25 - 55
Max exposure temperature

°C 70 (Max. exposure time: 24 h).
(transportation and storage)
Pipe characteristics
Diameter mm 32 ÷ 200
Thickness mm 1.5 -18.2
Pipe length (including the socket) mm 500 - 6000
Socket length mm 0 - 215
Material PVC-U, ABS
Wall type smooth compact

UM_100431_01
- 43 -
Chapter 2
2.14. SURROUNDING AREAS

The illustration shows the surrounding areas necessary to mark off the
operator's work zones, machine access areas, and product passage ar-
eas.
min
C 800 C
F
E A
G H
min min min min
800 800 800 800
D B
min B
800
min C
800
Key
A – Pipe infeed area
B – Operator control area
C – Perimeter area
D – Pipe unloading area
E – Reject pipe exit area
F – Zone for using optional haul-off controls
G – Pipe outlet and exit protection area
H – Maintenance area
Important
Areas A and E must be delimited with access prohibited to opera-
tors. Zone (D-G) must be delimited as described in the paragraph
3.10. - "Residual risks".
UM_100431_01
- 44 -
Chapter 2
2.15. NOISE LEVEL

These measurements were made in compliance with UNI EN ISO 3744
- UNI EN ISO 11201 standards.
The values were measured with the machine in standard operating mode
and with all the protection devices installed.
From the values of the equivalent continuous A-weighted sound pressure
measured at different points around the machine (see illustration) and ex-
pressed in dB (A), the following values are obtained.
– Average sound pressure level: Lpm = 79 dB (A)
– Normalised sound power level: Lw = 98.4 dB (A)
– Maximum instantaneous C weighted sound power level in the work-
place: Lpo = 82.5 dB (C).
76
77
78
77
79 00
10
76
79
78
3090
76
1545
6
76
11
35 10
48 00 00
10
UM_100431_01
- 45 -
Chapter 2
UM_100431_01
- 46 -
Chapter 3
SAFETY INFORMATION 3
3.1. GENERAL INSTRUCTIONS

– The manufacturer, during the designing and manufacturing stages, has
paid special attention to the aspects that might jeopardise the safety and
health of the personnel that operates the machinery. As well as compli-
ance with current applicable legislation, the manufacturer has adopted all
the "rules of good craftsmanship". The purpose of this information is to
make the user aware to pay special attention in order to foresee any risk.
There is no substitute for prudence. Safety also lies in the hands of all op-
erators that work on the machinery.
– Carefully read the instructions of the manual supplied with the machin-
ery and the ones directly fitted on the machinery, especially the ones con-
cerning safety.. A little time dedicated to the study of this manual will
prevent unpleasant accidents; it is always too late to remember what
should have been done when it has already happened.
– Pay attention to the meaning of the symbols of the plates fitted on the
machinery; their shape and colour are important for safety purposes.
Keep them readable and comply with their information.
– Do not tamper with, do not dodge, eliminate or bypass the safety devic-
es installed on the machinery. The non-compliance with this requirement
may cause serious risks for personnel’s safety and health.
– The personnel that carries out any type of operation during the entire
useful life of the machinery must have specific technical competence,
special skills and experience acquired and acknowledged in the specific
sector. The lack of these requisites may jeopardise the safety and health
of personnel.
– During operation only use the personal protection clothes and/or devic-
es listed in the instructions supplied by the manufacturer and the ones
provided for by current regulations on safety at work.
– During the normal use or for any intervention, keep the surrounding
area in adequate condition, especially the one accessing the controls, in
order to avoid jeopardising the safety and health of personnel.
– The aid of one or more helpers may be necessary during some stages.
In these cases it is advisable to adequately train and inform them on the
type of activity to be carried out, in order to avoid damages to the safety
and health of personnel.
UM_100431_01
- 47 -
Chapter 3
SAFETY INFORMATION
3.2. HANDLING AND INSTALLATION

REGULATIONS
– Always lift and move the machinery in compliance with the information
supplied by the manufacturer and directly marked on the packaging, on
the machinery and the user’s instructions.
– Never attempt to bypass any of the machine functions. The non-compli-
ance with this requirement may cause serious risks for personnel’s safety
and health.
– Personnel loading, unloading and moving the machine must be appro-
priately certified and experienced and must be skilled at operating any
lifting machinery used.
– Loading and transportation must be carried out using means with an ad-
equate capacity, anchoring the machinery in the points provided for by
the manufacturer. Persons authorised to carry out said operations must
possess specific skills and experience in order to safeguard their own
safety and that of other people involved.
– Before transferring the machinery on transportation means, make sure
the machine and its components are adequately anchored to the means
used and that their structure does not exceed the maximum dimensions
allowed. if necessary prepare the appropriate signals.
– All installation phases must be taken into consideration starting from the
execution of the general engineering phase. Before starting such phas-
es, as well as the definition of the installation area, the person authorised
to carry out these operations must, if necessary, prepare a "safety plan"
to safeguard the safety of people directly involved and strictly apply all
the laws, with special reference to the ones on movable work sites.
– After defining the machine installation area, identify with appropriate
signs and delimit the area to impede unauthorised access.
– During installation, respect the surrounding clearance areas indicated
by the manufacturer, and also take into account all the nearby working
activities. The implementation of this requirement has to be carried out
also in compliance with current regulations on safety at the work place.
– The installation and the connections must be performed in accordance
with the instructions supplied by the manufacturer. The person in charge
must also take into account all the statutory and legislation requirements,
providing workmanlike installation and connection operations. Once the
installation has been completed, before the utilisation stages, he must
verify if said requirements have been complied with by performing an
overall control.
UM_100431_01
- 48 -
Chapter 3
SAFETY INFORMATION
3.3. REGULATIONS FOR OPERATION AND USE

– The operator, as well as being adequately informed on the use of ma-
chinery, must possess skills and competence adequate to the type of
working activity to perform.
– Even after being adequately informed, during the first utilisation, if nec-
essary, simulate some operating manoeuvres to identify the controls, es-
pecially the ones for starting and stopping the machinery and their main
functions.
– The machine must only be used for the applications intended by the
manufacturer. Only use the machinery for the purposes intended by the
manufacturer.The employment of the machinery for improper uses may
cause risks to the safety and the health of personnel and economic loss.
– The machinery has been designed and manufactured to satisfy all the
operating conditions indicated by the manufacturer. Using the machine
for purposes other than intended is considered improper use and is thus
prohibited, as it may jeopardise the safety and health of personnel and
cause economic loss.
– Do not use the machinery with the safety devices not properly installed
and efficient. The non-compliance with this requirement may cause seri-
ous risks for personnel’s safety and health.
– With the machine in an automatic cycle, all maintenance and adjust-
ment interventions are prohibited. The only authorised operations are
those to stop, switch off the machine and adjusting the work parameters
from the control panel.
– The only actions permitted are as follows:
Shut-down of the operating cycle Turning the machine off.
Adjusting operating parameters from the control panel.
Topping up the lubricator for the pneumatic system.
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3.4. REGULATIONS FOR ADJUSTMENT AND

MAINTENANCE OPERATIONS
– Keep the machine in maximum efficiency conditions and perform all the
scheduled maintenance operations provided by the manufacturer. Good
maintenance will result in better performance, a longer operating life and
keep the safety requirements unchanged over time.
– It is forbidden to lubricate, clean, adjust mechanism in motion.
– Maintenance and format changes on the machine are to be carried out
strictly as indicated in the manual, with the machine disconnected from
energy supplies (electrical, pneumatic, etc.), or set up to work in "MAN-
UAL" mode.
– Before carrying out any maintenance or adjustment operations, activate
all the safety devices provided for and evaluate if it is necessary to inform
the operating personnel or the personnel nearby. In particular, identify
the surround areas with appropriate signs and impede access to all de-
vices which could cause conditions of unforeseen danger or risks to
health and safety if activated.
– If the intervention procedures require the operator to access dangerous
areas, switch off the electric cut-off switch to ensure that the machine is
safe. To eliminate the presence of additional risks, assess if residual en-
ergy is present.
– Before performing any operation on pressured lines and/or disconnect-
ing the elements, check that the line has been de-pressurised and does
not still contain hot fluid.
– The maintenance and adjustment interventions must be carried out by
authorised personnel that must activate all the necessary safety condi-
tions and comply with the specified procedures contained in the docu-
mentation supplied by the Manufacturer.
– All the maintenance operations require a specific technical competence
or special skills, must be carried out only by qualified personnel, with a
recognised experience in the specific sector of intervention.
– Replace excessively worn components with original replacement parts.
Use the oils and greases recommended by the manufacturer. This will
ensure correct machine operation at the safety levels specified.
– Do not dispose of polluting materials in the environment. Dispose of in
compliance with current regulations on the matter.
– when maintenance or repairs are finished, before restarting the ma-
chine, check that no tools, rags or other material has been left near mov-
ing components.
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3.5. SAFETY RULES CONCERNING ELECTRICAL

EQUIPMENT
Electrical equipment has been designed and built in compliance with ap-
plicable legislation. This legislation also specifies the ambient conditions
required for operation.
The following list specifies ambient conditions necessary to ensure cor-
rect electrical equipment function.
– Ambient temperature must be between 5°C and 40°C.
– Relative humidity must be between 50% (measured at 40°C) and 90%
(measured at 20°C).
– The installation area must not be subject to or contain sources of elec-
tromagnetic interference or radiation (X rays, laser light etc.).
– The installation area must not contain potentially explosive or flamma-
ble mixtures of gases or dust.
– No contaminant or corrosive products (acids, chemicals, salts etc.) may
be used during production and maintenance. Any products used must be
kept away from electrical components.
– The ambient temperature during transportation and storage must be
between -25 °C and 55 °C. Electrical equipment may be exposed to tem-
peratures up 70 °C, provided that exposure time does not exceed 24
hours.
– The electrical equipment will function correctly up to an altitude of 1000
m above sea level.
– The cross section of the power cable must be adequate for the rated
power and current values indicated in the technical specifications and on
the "identification plate" affixed to the machine.
– The power cable must be adequately protected to withstand the speci-
fied short-circuit current.
If any of the aforementioned conditions, indispensable for correct
operation of the electrical equipment, cannot be met, any additional
measures necessary to ensure safe operating conditions (e.g. spe-
cial electrical components, air conditioning systems, etc.) must be
defined during the contractual stage, etc.).
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SAFETY INFORMATION
3.6. SAFETY REGULATIONS ON THE

ENVIRONMENTAL IMPACT
Each organisation is responsible for applying procedures that must be
identified and evaluated and is to check the effect their activities (prod-
ucts, services, etc.) have on the environment.
The procedures to carry out to identify significant environmental impacts
must take the following factors into consideration:
– Emissions into the atmosphere
– Discharge of liquids
– Waste management
– Pollution of the soil
– Use of raw materials and natural resources
– Local problems in relation to the environmental impact
In order to minimise the environmental impact the manufacturer has pro-
vided some indication below, that must be taken into account by all of
those that, for any reason, work with the machine during its lifespan.
– All packing components are to be disposed of in compliance with cur-
rent regulations.
– During installation, make sure that there are sufficient changes in the
ambient air to prevent concentrations that of air that is harmful for the op-
erators.
– During operating and maintenance do not dispose of pollutants (oils,
greases, etc.) into the environment, and dispose of the various products
separately in compliance with current laws in this regard.
– Keep noise emissions at minimum levels to reduce noise pollution.
The Waste of Electrical and Electronic Equipment may contain hazard-
ous substances with potentially harmful effects on the environment and
the health of people. It is therefore recommended that disposal is carried
out in a correct manner.
– When decommissioning the machine, separate all the components ac-
cording to their chemical characteristics and dispose of them separately
in compliance with current laws in this regard.
– In reference to the WEEE directive (Waste Electrical and Electronic
Equipment), the user must separate the electrical and electronic compo-
nents during disposal and dispose of them in the appropriate authorised
waste collection centres, or deliver them to the retailer still installed when
making a new purchase.
– All components that must be separated and disposed of in a specific
manner are marked with a special sign.
– The illegal disposal of Waste Electrical and Electronic Equipment
(WEEE) shall be punished with sanctions governed by the laws applica-
ble in the territory where the infringement is ascertained.
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SAFETY INFORMATION
– In effect to the European directives (2002/95/EC, 2002/96/EC, 2003/

108/EC) in Italy for example, a legislative decree was issued (No. 151 is-
sued on July 25 2005) that foresees an administrative penalty of €
2000÷5000.
3.7. SAFETY SYMBOLS DESCRIPTION

Some of these signals are applied on the machine. For their position see
3.8. - "Signs position". Their meaning is specified on their side.
A – Do not remove safety devices with machine in motion.
B – It is forbidden to repair, lubricate, adjust, clean mecha-

nism in motion.
C – Do not place your hands in the opening.
D – It is forbidden to go over the barrier, when the machine is

in operation.
E – Do not enter when the machine is running.
F – It is forbidden to stop or pass in the working rage of the

machine.
G – Do not convey and lift by means of trolleys.
H – It is forbidden to walk on the bench.
I – It is compulsory to wear protective gloves.
L – It is compulsory to wear a safety helmet.
M – The use of protective filters for the eyes is compulsory.

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SAFETY INFORMATION
N – The device, indicated on the plate, must be used in com-

pliance with the procedures specified in the use and mainte-
nance manual.
O – It is compulsory to lift the machine from the lifting points

using a hook device with an adequate load capacity.
P – Danger of electric shock.
Q – Danger of squashing.
R – Danger of pipes fall.
S – High temperature walls.
T – Danger of falling
U – Danger of cutting upper limbs.
V – Danger of injury to the eyes.
W – Danger of splinters.
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SAFETY INFORMATION
3.8. SIGNS POSITION

The following illustration show the locations of the safety signs. Their
meaning is described in 3.7. - "Safety symbols description".
Important
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Ensure that all safety signs are clearly legible at all times; replace
any signs that are not clearly legible, installing the new sign in the
original position.
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SAFETY INFORMATION
3.9. DESCRIPTION OF SAFETY DEVICES

The illustration indicates the position of the devices.
D
D
F
F
E
L
G
H
F
B
C
P
L
F
F
Q B
A – Main electric cut-off switch (lockable): used to turn the electrical

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power supply on and off. The door is lockable to prevent unauthorised

use and to prevent access to the electrical panel when power is on.
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SAFETY INFORMATION
B – Emergency stop button: immediately stops every organ on the ma-

chine. After restoring normal operating conditions, the button must be
manually released to enable machine restart.
C – Mode selector: this is used to operate in safety conditions during
commissioning, regulation, maintenance, etc. operations where it is nec-
essary to operate with one or more protection devices disassembled or
neutralised.
D – Warning light: signals the operating conditions of the machine in
combination with the warning buzzer.
E – Electrical panel closure: is equipped with a removable key to pre-
vent unauthorised access.
F – Fixed cover: prevents any access to the dangerous areas of the ma-
chine.
G – Interlocked mobile guard: belling cycle area.This is a guard asso-
ciated with an electrical interlocking device. When the guard is opened,
the machine stops in an emergency condition. The restart of the machine
is allowed only when the guard is closed.
H – Interlocked mobile guard: belling cycle and pipe clamp area.This is
a guard associated with an electrical interlocking device. When the guard
is opened, the machine stops in an emergency condition. The restart of
the machine is allowed only when the guard is closed.
L – Fixed cover: prevents any access to the dangerous areas of the machine.
M – Maximum pressure valve: discharges the pressure from the water
system for cooling the pipe edge when the calibration value is reached
(present with the boosted air oven installed) (only for UNIBELL1 200 E,
UNIBELL1 200 RE versions).
P – Bench extension: prevents any access to the dangerous areas of
the machine.
Q – Interlocked mobile guard: maintenance area. This is a guard con-
nected to an electrical interlocking device. When the guard opens, the
machine stops in emergency conditions. The restart of the machine is al-
lowed only when the guard is closed.
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3.10. RESIDUAL RISKS
All the functional units
Danger - Warning
Danger of scalds/burns.
During the operation, the ovens reach very high temperatures. After be-
ing switched off, the ovens reach temperatures near ambient values only
after a relatively long time that cannot be precisely forecast. Therefore,
before carrying out any operation, switch the machine off and disconnect
it from all energy sources and take care to avoid accidental contact with
the oven parts. In particular, before carrying out interventions near or on
the ovens, make sure that the heating elements (lamps or resistances)
are switched off and wait until the temperature has dropped below 50°C.
Record the temperature value without touching the oven parts, using a
suitable infra-red thermometer. The use of protective gloves is compul-
sory.
Danger - Warning
Danger of UNEXPECTED MOVEMENT of mechanical parts.
– In the pneumatic system (works with medium pressure air, 6÷7 bar),
sudden drops in pressure, due to broken pipes, or disconnected lines,
can cause non-intentional movement of the mechanical parts and/or
whiplash of the flexible hoses.
If necessary, discharge the residual pressure from the machine's pneu-
matic system.
As the technician must climb onto the bench in order to adjust the pipe
haul-off device and pipe rotating clamp, he must wear shoes with slip-
proof soles and be very careful not to slip, trip or fall.
Danger - Warning
Danger of SLIPPING/FALLING from the machine.
The technician must climb onto the ladder or bench in order to access
certain machine units for adjustments or maintenance purposes. In these
cases, he must wear shoes with slip-proof soles and be very careful not
to slip, trip or fall.
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SAFETY INFORMATION
Danger - Warning
DANGER OF IMPACT/CRUSHING.
– If, on the pipe unloading side of the belling machine, no automatic pipe
collection or sorting equipment is fitted (available on request), the cus-
tomer is held directly responsible for providing suitable safety measures
for the operator and other personnel, in order to prevent them from being
hit by pipes being unloaded from the machine after belling and to main-
tain safety distances from the pipe clamps and from the exposed forming
area. In particular, the Customer must fit a safety surround to shut off the
area.
– To load and discard the cut pipes to be belled, the ends of the pipe
transfer bench must remain open; The customer is held directly respon-
sible for providing suitable safety measures for the operator and other
personnel, in order to maintain safety distances from incoming/outgoing
pipes to the machine. In detail, the customer must make sure the pipes
are supported and accompanied to avoid them dropping directly on the
floor.
– All persons interacting with the machine must wear protective footwear.
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SAFETY INFORMATION
Danger - Warning
Danger of INHALING GASES/TOXIC FUMES
The incorrect setting of the parameters of the pipe heating process or a
failure of the control and adjustment systems of such parameters may
determine a thermal state of the pipe walls in the oven, resulting in the
triggered combustion of the plastic material and the emission of fumes.
The fumes consist of:
– carbon dioxide (CO2)
– water (H2O)
– other substances whose type and concentration varies according to the
resin and the additives that make up the plastic material.
Some of these substances are highly toxic, for example the carbon mon-
oxide (CO) and the hydrochloric acid (HCl). The latter, in particular, un-
dergoes a massive development during PVC combustion.
Danger - Warning
Danger on the extrusion line
– In case of failure of the pneumatic supply, the pipe haul-off device stays
in the low position. It hence becomes an obstacle for the pipe entering
the extrusion line. It can cause shifts on the line machines and potential
dangers and injuries to people and things. In this case, stop the entire line
as soon as possible.
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SAFETY INFORMATION
3.11. OPERATING MODE DUE TO EMERGENCY

CONDITION
During automatic operation, if a fault with machine functions block is de-
tected, in order to prevent accidents and restart the machine in safety
conditions, proceed as follows:
1 – Press one of the emergency buttons (6) on the machine (the one clos-
est to hand), or open one of the mobile guards (G-H-Q).
On the terminal display (4), the "EMERGENCY DEVICE ENABLED"
alarm is activated (see the terminal "Operating Guide") and the warning
light switches on (2).
When the command is activated, the machine stops in the "pipe standby"
position and the listed conditions arise.
– The machine is drained of all residual energy.
– The haul-off device lifts up.
– The rotating clamp rises.
– The pipe lifting beams lower.
– The electric motors stop.
– The E.P. chamber is de-pressurised. The machine is still supplied with
water power.
Only for air-ventilated oven:
–the oven heating elements and fan remain activated.
Important
If the causes of the arrest call for the entrance of the operator within
the dangerous areas, it is necessary to proceed as indicated in or-
der to ensure adequate safety conditions.
- Stop pipe feeding.
- Turn the main electricity cut-off switch (1) to "O" (OFF) position to
deactivate electricity supply.
- Isolate the machine from all power sources and discharge residual
energy (see 6.6. - "Deactivating the energy sources (machine dis-
connected)").
- Open or remove the safety guards to access the operation area.
1 – After having normalised the operating conditions, check that no tools,
rags or other materials have been left near moving parts.
2 – Close and refit all the previously removed guards.
3 – Release the emergency button (6) to enable machine restart.
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4 – Restart the machine in "manual" mode (see 6.5., sec. "Activating the
machine in manual mode") or else in automatic mode (see 6.5., sec. "Ac-
tivating the machine in automatic mode").
2
3
6
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INFORMATION ON HANDLING AND INSTALLATION
OPERATIONS 4
4.1. RECOMMENDATIONS FOR HANDLING

AND INSTALLATION
Important
When moving and installing the machine, observe the indications
provided by the manufacturer on the box, on the machine itself and
in the user manual. The person authorised to perform these opera-
tions must, if necessary, arrange for a "security plan" to ensure the
safety of the people directly involved.
4.2. PACKING AND UNPACKING

– The packaging is designed to save space and differs depending on the
transportation method used.
– To make the transportation easier, shipping may be done with some
components disassembled and appropriately protected and packaged.
– Certain parts, electrical components in particular, are protected with
moisture-proof film.
– All information necessary for loading and unloading is given on the
packaging.
– The machine components must only be unpacked once the personnel
authorised by the manufacturer start installing the machine.
– Depending on the effective requisites for installation, the authorised
personnel will unpack the machine components in the manner deemed
most appropriate and check that all parts are in good condition.
– Keep all packaging materials (crates, pallets etc.) for future use and dis-
pose of all protective materials (plastic film, polystyrene etc.) in compli-
ance with applicable legislation.
WITHOUT PACKAGING PACKAGING ON LOADING PLATFORM PACKAGING IN CRATE

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INFORMATION ON HANDLING AND INSTALLATION OPERATIONS
4.3 TRANSPORT
– Depending on a number of fac-
tors, including destination, different
methods of transportation may be
used.
– The illustration shows the most
commonly used solutions.
Transport vehicles
– Anchor the machine to the vehicle
appropriately to prevent movement
during shipping.
Important Lifting devices (*)

(*) Prohibited lifting with forklift
concerns the bench only.
4.4. CHECKING "PACKING LIST" AND STATE

OF PACKAGES
Each shipment is accompanied by a document containing a list of all
packages with descriptions.
Upon receipt of the packages, check that the contents of the packing list
effectively correspond to the materials received and check that all pack-
ages are undamaged.
Important
If any damage or missing parts are noted, contact the manufacturer
in order to rectify the situation.
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Chapter 4
4.5. HANDLING AND LIFTING

– The dismantled parts of the machine may be handled with lift equipment
of suitable load capacity.
An identification plate (in English) is applied to each part, indicating ma-
chine model, sub-assembly and weight.
Before doing any and lifting, check the information on the plate and posi-
tion the centre of gravity of the load.
– The illustrations show the most common lifting and handling mode.
WITHOUT PACKAGING PACKAGING ON LOADING PLATFORM PACKAGING IN CRATE
Machine model
Unit identification
Weight
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Chapter 4
List of dismantled parts
2
4
The following table lists the various units of the machine, along with their
dimensional characteristics and weights.
Table 4.1: List of dismantled parts
Ref. Component Description Weight (kg)
1 Machine body HEAD 2750
2 Bench BENCH 1200
Conveyor CHANNEL 140
3
Conveyor (motorised) CHANNEL 225
EXTENSION
4 Bench extension 30
BENCH
5 Protection panels - ---
Mobile guard for protecting the
6 - 60
belling cycle
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Chapter 4
4.6. WAREHOUSING AND STORAGE

PROCEDURES
– Upon receipt of the material, the purchaser must provide an adequate
area for the storage of the packages.
– To prevent the material from posing a risk to personnel or deteriorating,
the storage area must be covered (preferably indoors) and accessible
only to authorised personnel.
– Apart from having a stable floor with an adequate load coefficient, the
warehouse area must also be free of any fire and/or explosion risk, must
comply with the humidity and temperature requisites, and must be suita-
bly illuminated (see 2.13. - "Technical data").
– We recommend establishing the storage area in the immediate vicinity
of the installation area to minimise transportation distances during instal-
lation.
Caution - Note
In the event of prolonged storage, periodically check that the nec-
essary storage conditions are still met.
4.7. CHARACTERISTICS OF THE

INSTALLATION ENVIRONMENT
Important
Certain environment conditions are required for the installation ar-
ea.
The installation area must meet the following requisites.
– Luminosity compliant with European standards (recommended levels
250 to 650 lux).
– The installation area must be well ventilated.
– Adequate relative humidity and temperature (see 2.13. - "Technical da-
ta").
– The floor must be perfectly stable, level and capable of sustaining the
weight of the machine to ensure proper support.
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Chapter 4
4.8. MACHINE INSTALLATION

Proceed as follows.
1 – Identify the installation site indicated in the layout. For more informa-
tion, contact the manufacturer's support service.
2 – If necessary, identify the exact position and mark out the site to en-
sure that the machine is positioned correctly.
3 – Position the machine so that it is aligned with the pipe feeding axis.
4 – Remove the lifting device.
5 – Check that the belling (X) and pipe feeder (Y) axes are parallel and
level.
Important
Position the level as shown in the figure.
6 – Operate the support feet (B) to adjust the height of the axis (X) and to
carry out any levelling.
91
0m
m
y
x
B
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Chapter 4
7 – Lift the bench (C) and rest it against the machine (A).
Important
Lift the bench via the indicated lifting points. Do not use forks for
lifting.
8 – Remove the lifting device.
9 – Adjust the support feet (D) to level the bench parts (C) and align the
fixing holes.
10 – Fix the bench (C) to the machine (A) using the screws.
D
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Chapter 4
11 – Remove guard (L).

12 – Position the conveyor (F) and fix it to the bench (C) with the its screws.
13 – Put back the guard (L).
14 – Remove the lifting device (if necessary).
F
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Chapter 4
15 – Assemble the bench extension (M) and fix it with the screws.
16 – Assemble and fix the warning light (N).
17 – Remove all the lifting eye-bolts.
NB: keep them for future transfers.
18 – Mount the guards (P) and fasten them with the screws.
M
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Chapter 4
19 – Make the connections for the pneumatic, water and electric systems,
following the enclosed diagrams.
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Chapter 4
20 – Fit the belling mobile guard protection (S) using the relative screws.
S
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Chapter 4
4.9. RECOMMENDATIONS FOR UTILITY

CONNECTIONS
Important
Connection to utilities must be performed in accordance with the in-
dications given by the manufacturer in the attached layouts. Per-
sons authorised to carry out utility connections must be suitably
skilled and have certified experience in the field, and must comply
with all applicable legislation and carry out the connection work to
recognised standards. Once the connections are complete, the ma-
chine must be generally inspected to ensure that all requisites have
been met before starting the machine.
4.10. ELECTRICAL CONNECTION
Caution - Note
Disconnect the mains power supply before carrying out any opera-
tion.
Proceed as follows.
1 – Insert the power supply cable (A) in the cable grommet (B).
2 – Connect the power cable to the terminal board (C), respecting the
connections of the phases to the clamps as shown in the table.
Table 4.2:
Cable Clamp
Phase L1 R
Phase L2 S
Phase L3 T
Neutral N
Earth Yellow / Green (PE)
Important
The short-circuit current at the point of connection must not exceed
10 kA (regulated short-circuit current - icc) and 17 kA (peak short-
circuit current - ipk).
The power cable must be adequately protected to withstand the
specified short-circuit current.
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Chapter 4
3 – Start the machine in "manual" mode (see 6.5., sec. "Activating the
machine in manual mode").
4 – Activate the rotation of the pipe haul-off device and check it rotates in
the right direction.
Important
If the rotation direction is wrong, disable the main electric cut-off
switch and invert the phase cables.
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Chapter 4
4.11. PNEUMATIC CONNECTION

Proceed as follows.
1 – Connect the pneumatic supply tube to the tap (A).
2 – Turn on the compressed air supply to the machine and check that the
pressure is correct (see 2.13. - "Technical data").
4.12. WATER CONNECTION

Proceed as follows.
1 – Connect the supply tube to the tap (B).
2 – Connect the drainage tube to the tap (A).
3 – Connect the chilled water supply tube to the tap (D).
4 – Connect the chilled water drainage tube to the tap (C).
B A D C
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Chapter 4
4.13. REMOVING TRANSPORT RETAINERS
Important
To prevent unexpected shifting of some components during trans-
portation, they should be suitably blocked. These devices are indi-
cated by a plate with the following warning: REMOVE THIS DEVICE
BEFORE OPERATING THE MACHINE. THIS DEVICE IS USED FOR
TRANSPORT ONLY.
Remove retainers and keep for future machine transfer.
4.14. TESTING THE MACHINERY

– Before final testing and putting the machine into commission, the au-
thorised installer must check that the entire machine is safe and that the
perimeter area is suitably demarcated and indicated in compliance with
applicable occupational safety laws and regulations.
– During initial machine testing, evaluate if all safety conditions are met
and only start the machine if they are.
Important
Initial machine testing must be conducted according to a precise
procedure by qualified personnel authorised to do so by the manu-
facturer.
– After initial machine testing, if necessary, instruct and train the line man-
ager to give him or her all the skills necessary to operate the machine in
complete safety in compliance with applicable legislation.
– To ensure effective operator training, assess the skills of the operator
and the skills effectively needed for the job, in order to provide him or her
with the knowledge necessary to understand the capabilities of the ma-
chine and to operate the machine in complete safety.
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Chapter 5
INFORMATION ON ADJUSTMENTS 5
5.1. RECOMMENDATIONS FOR

ADJUSTMENTS
Important
Before carrying out any maintenance work, activate all safety de-
vices and, if necessary, inform all personnel working in the vicinity
of the machine. In particular, identify the surround areas with ap-
propriate signs and impede access to all devices which could
cause conditions of unforeseen danger or risks to health and safe-
ty if activated.
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INFORMATION ON ADJUSTMENTS
5.2. ADJUSTING THE CHAIN (BENCH)

Proceed as follows.
1 – Stop the machine and turn the main electric cut-off switch to "O"
(OFF) to switch off the electrical power.
2 – Isolate the machine from all power sources and discharge residual
energy (See 6.6. - "Deactivating the energy sources (machine discon-
nected)").
3 – Remove the guards (C).
4 – Loosen the screw (A).
5 – Move the tensioner (B) to adjust the chain tension (D).
6 – Tighten the screw (A).
Important
Do not over-tighten the drive, as this could damage the rotating
parts.
Caution - Note
Before refitting the guards and restarting the machine, check that
no tools or other materials have been left near moving parts.
7 – Reassemble the guards (C).
8 – Restart the machine in "manual" mode to make sure it is working cor-
rectly (see 6.5., sec. "Activating the machine in manual mode").
D
D
B A B A
C
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Chapter 5
5.3. DRIVE CHAIN ADJUSTMENT (HAUL-OFF)

Proceed as follows.
energy (see 6.5., sec. "Deactivating the electrical power supply (machine
off)").
3 – Remove guard (A).
4 – Loosen the screw (B).
5 – Press the tensioner (C) towards the chain to tension it and tighten the
screw (B).
Important
parts.
Caution - Note
6 – When finished, refit the guard (A).
7 – Restart the machine in "manual" mode to verify proper operation (see
6.5., sec. "Activating the machine in manual mode").
B C
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Chapter 5
5.4. CHAIN ADJUSTMENT (OPTIONAL

MOTORISED CONVEYOR)
Proceed as follows.
energy (see 6.6. - "Deactivating the energy sources (machine discon-
nected)").
3 – Dismantle the guard (C).
4 – Use the screw (A) and counter nut to adjust the tension of the chain
(B).
Important
parts.
To check proper tensioning, verify the promptness in changing the
roller rotation direction.
Caution - Note
5 – Refit the guard (C).
6 – Restart the machine in "manual" mode to make sure it is working cor-
rectly (see 6.5., sec. "Activating the machine in manual mode").
C
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6.1. RECOMMENDATIONS FOR USE AND

OPERATION
Important
Accidents and injuries related to the operation of the machine de-
pend on numerous factors, many of which cannot be prevented or
controlled. While some accidents may be attributable to unforesee-
able external factors, the majority are caused by human error and
inappropriate practices.
In addition to being authorised and properly documented, if neces-
sary, before the initial use they should simulate some operations to
identify the main controls and functions. Only actuate the uses en-
visaged by the manufacturer and do not tamper with any device to
obtain a performance other than that envisaged. Before using,
check that the safety devices are installed and working correctly.
Users must ensure that all the aforementioned requisites are met,
and must read the descriptions of the machine commands and
functions thoroughly.
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6.2. DESCRIPTION OF CONTROLS

The illustration shows the locations of the controls on the machine.
In the event of a configuration with no (b), all the controls are positioned on the panel (a).
2
3
1
a
6 11 12
7 8 9 10
4
14 15 18
13 16 17
14
19
6
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Table 6.1: Description of machine commands

Pos. Symb. Description Function Indication
Main electric cut-off Used to turn the electrical pow- Pos. "O" (OFF): power off.
1
switch (lockable) er supply on and off. Pos. "I" (ON): power on.
Signals that the machine is in

alarm state. It turns off when
2 Warning light (red light)
the operating conditions have
been restored.
Signals that the machine is in

3 Acoustic buzzer Press the button (12) to deactivate.
alarm state.
For information on using and pro-

Used to display and set produc- gramming the terminal, refer to the
4 Operating terminal
tion parameters. "Operation Guide" terminal at-
tached.
Press in situations of impending

Used to stop the entire machine danger.
6 Emergency button in situations of impending dan- For more information, see 3.11. -
ger". "Operating mode due to
emergency condition".
Pos. " ": manual operation.
Pos. "0": operation disabled.

With the mode selector (7) in posi-
tion "0", the operating units of the
Used to select the machine op- machine move into the start posi-
7 0 Mode selector
erating mode. tion of the cycle and it is possible to
open the mobile guards (if pres-
ent).
Pos. " ": automatic cycle
start enabled.
Press to activate: the indicator light

switches on.
Important
8 Button (white light) Used to start automatic cycle.
This control is only enabled with
the mode selector (7) in position
" ".
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Press to activate: the indicator light

starts to flash.
Flashing: positioning phase in pro-
gress.
Used to correctly position ma-
9 0 Button (green light)
chine devices for operation.
Important
When the indicator light remains
on, the "positioning" phase is
completed.
Pos. " ": Protection ena-
bled.
Pos. " ": Protection disa-
bled.
Key switch To open the mobile guards without
Used to activate and deactivate causing an emergency machine
10 Important the pipe unloading interlocked stop, turn the mode selector (7) to
Control reserved for mobile guards.
" / " and the Key
"expert technician".
switch (10) to " ".
For the correct use of the selector,

refer to paragraph 6.15. - "Check-
ing the thermal state of the pipe to
be belled".
Used to switch on the control

panel at first machine start, af- Press to activate: the indicator light
11 Button (blue light)
ter a power outage or after an switches on.
emergency arrest.
Press to deactivate the warning

buzzer: the indicator light switches
off.
Used to reset the alarms (siren Important

12 Button (orange light)
and lights). The machine remains in alarm
state until normal operating con-
ditions are restored, as sig-
nalled by the flashing indicator
(15).
Use to transfer data required for

13 USB socket Used for housing a USB key.
using the software.
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2
3
1
a
6 11 12
7 8 9 10
4
14 15 18
13 16 17
14
19
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Used to stop the automatic op-

14 Button (black) Press to stop the cycle.
eration cycle of the machine.
Press to stop.
Button (white light) Heating control reservation.
Used to temporarily stop the Important
15 Important automatic operation cycle of For the correct use of the but-
Control reserved for the machine, in order to check ton, refer to paragraph 6.15. -
"expert technician". the temperature of the pipe. "Checking the thermal state of
the pipe to be belled"
Press and hold to move the oven

Used to activate, momentarily forward and start the heating
suspend or interrupt the heat- phase.
ing of the oven, in order to To temporarily suspend the pipe
check the state of the pipe fol- heating cycle, press and release
lowing heating. the button before the complete
withdrawal of the oven. Press the
Important button again to restart the pipe
16 1 Button (black)
The command is enabled heating cycle from the point in
only when the machine is in which it was interrupted.
automatic mode (mode se- To definitively interrupt the pipe
heating cycle, press the button and
lector to position " ") keep it pressed down until the oven
and the indicator button (8) has completely withdrawn. The
on. pipe is transferred to the socket
belling station.
Used to activate, go to the next Press and hold to start the belling
phase or stop the belling cycle of the socket.
in progress. Press and release the button to go
immediately to the next phase of
the belling cycle without having to
Important
wait for the work time pre-set from
The command is enabled
17 Button (black) the operating terminal
only when the machine is in
(4) (see "Operating guide" of the
automatic mode (mode se-
terminal).
lector to position " ") To definitively interrupt the belling
cycle, press the button and keep it
and the indicator button (8) pressed down until the carriage
on. has completely withdrawn.
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2
3
1
a
6 11 12
7 8 9 10
4
14 15 18
13 16 17
14
19
6
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Press button together with control

on the operating terminal (4) to
move the parts concerned.
Button (white light)

Important
Used to activate the machine's The command is only enabled
18 Important manual controls when the inter- with the machine in manual
Control reserved for locked mobile guards are open. mode (mode selector on
"expert technician".
" ") and with the key se-
lector (10) in position " ".
Selector switch (2 posi- Used to enable/disable the start Pos. 1: start enabled.
19
tions) of the haul-off. Pos.2: start disabled.
Pos. "R": carriage moving forward.

Selector (2 positions, Pos. L: carriage retracting.
optional)
Used to start the positioning of
Important
20 the motorised carriage (if pres-
Important
ent) of the heating oven. For the correct use of the com-
Control reserved for mand, refer to paragraph 6.8 -
"expert technician". "Adjusting the position of the
motorised oven (optional)".
Important
For more details, see the electrical diagram.
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2
3
1
a
6 11 12
7 8 9 10
4
14 15 18
13 16 17
14
19
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6.3. ACTIVATING AND DEACTIVATING THE

PNEUMATIC POWER SUPPLY
A description of the procedures to obtain the various machine power status conditions.
Important
The position of the main electric cut-off switch does not have any
effect on the following procedures.
Enabling of pneumatic power supply

1 – Close the tap (A).
2 – Open the tap (C).
3 – Open the tap (H).
4 – Check, on the pressure gauge (L) that the pressure is correct (see
2.13. - "Technical data"). If necessary, adjust the pressure by means of
the regulator (M).
5 – Turn the main electricity cut-off switch (1) to pos. "I" (ON).
Important
With the main electric cut-off switch (1) on "O" (OFF), all the resid-
ual pneumatic energy is discharged.
Disabling of pneumatic power supply

1 – Close the tap (H).
2 – Check that the pressure gauge (L) indicates that the pneumatic sys-
tem pressure is 0 bar.
Caution - Note
Pneumatic energy is present in the tanks.
Discharging the residual pneumatic power

1 – Close the tap (C).
2 – Close the tap (H).
3 – Check that the pressure gauge (L) indicates that the pneumatic sys-
tem pressure is 0 bar.
4 – Open the tap (A) to discharge the residual pressure from the tanks.
5 – Turn the main electric cut-off switch (1) to pos. "O" (OFF).
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M
H
C A
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WATER SUPPLY
A description of the procedures to obtain the various machine power status conditions.
Important
The position of the main electric cut-off switch does not have any
effect on the following procedures.
Activating the water supply

1 – Open the water inlet and outlet taps (D-E-F-G).
2 – Start up the external cooling unit.
Deactivating the water supply

1 – Stop the external cooling unit.
2 – Close the tap (D).
3 – Turn on the taps (E-G).
Discharging the residual water energy

2 – Close the taps (D-F).
3 – Turn on the taps (E-G).
D C
E F G
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ELECTRICAL POWER SUPPLY
Activating the machine in "0" mode

Proceed as follows.
1 – Ensure that all safety devices are installed and functioning correctly.
2 – Start the pneumatic power supply (see 6.3. - "Activating and deacti-
vating the pneumatic power supply").
3 – Start the water supply (see 6.4. - "Activating and deactivating the wa-
ter supply").
4 – Turn the mode selector (7) to "0".
6 – Press the button (11) to restore voltage to electrical controls.
7 – Check that no alarm message is shown on the display. If this is not
the case, restore the conditions to eliminate the signalled alarm.
11
1
7
4
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Activating the machine in manual mode

Proceed as follows.
3 – Start the water supply (See 6.4. - "Activating and deactivating the wa-
ter supply").
8 – Turn the mode selector (7) to " ".
9 – Prepare the machine for the specific pipe characteristics and the di-
mensions of the socket to be made (see 6.8. - "Format change")
10 – Use the operating terminal controls (4) to start the machine parts
moving.
11 – To exit manual operation mode, turn the mode selector (7) to "0".
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1
7
4
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Activating the machine in manual mode with guards excluded
Caution - Note
The operations described below should only be carried out by an
expert operator, since the machine can also be started with the pro-
tections excluded.
Proceed as follows.
3 – Start the water supply (see 6.4. - "Activating and deactivating the wa-
ter supply").
9 – Turn the key switch (10) to " " in order to disable the safety
guards.
Danger - Warning
In these conditions, the outlet guard is disabled. The technician
must pay the utmost attention when carrying out the following inter-
ventions, to avoid any possible safety risk if they are carried out
with the guard open.
10 – Before restarting close the guards.
11 – Use the button (22) and the operating terminal commands (4) simul-
taneously to activate the movements of the machine parts (refer to the
"Operating Guide" of the terminal).
12 – Turn the key selector (10) to " "in order to disable the safety
guards.
13 – To exit manual operation mode, turn the mode selector (7) to "0".
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7 10
4 1
20
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Activating the machine in automatic mode

Proceed as follows.
3 – Start the water supply (See 6.4. - "Activating and deactivating the wa-
ter supply").
5 – Turn the main electricity cut-off switch (1) to "I" (ON).
8 – Check that the machine is set up for the specific pipe characteristics
and the dimensions of the socket to be made (see 6.8. - "Format
change").
9 – Set the production parameters by means of the operating terminal
(see "Operating Guide" of the terminal).
10 – Use the operating terminal (4) to switch on the air oven and the fan,
then wait until the temperature reaches the set value.
12 – Press the button (9). The "positioning" phase of the machine begins.
The button indicator light starts to flash.
When the indicator light remains on, the "positioning" phase is completed.
13 – Press the button (8) to enable automatic operation. The button light
switches on.
The indicator light of the button (9) will switch off.
14 – Start the pipe feed.
After these operations, the machine starts to work in automatic mode.
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7 8 9
4
1
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Deactivating the electrical power supply (machine off)

Proceed as follows.
1 – Use the controls on the operating terminal (4) to deactivate the heat-
ing of the oven.
2 – Switch off the oven's heating elements, then wait until the tempera-
ture falls below 100°C before switching off the oven fan.
Caution - Note
The machine is still supplied with water power.
4 1
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6.6. DEACTIVATING THE ENERGY SOURCES

(MACHINE DISCONNECTED)
Proceed as follows.
3 – Switch off pneumatic power supply (see 6.3. - "Activating and deacti-
4 – Disable the water supply and release any residual water energy (See
6.4. - "Activating and deactivating the water supply").
1
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6.7. STOP AND RESTART MODE

The machine in the automatic cycle can stop or be stopped for the following reasons:
– Stopping the current procedure and restart (see p. 104).
– Emergency stop and restart (see 3.11. - "Operating mode due to emer-
gency condition", page 61).
– Automatic stop for alarm and restart conditions (see p. 104).
– Stop due to blackout and restart (see p. 106).
– Arrest due to end of production and restart (see p. 107).
– Normal stop (machine without pipes) (see p. 108).
– Manual stop and restart (machine with pipes) (see p. 108).
Stopping the current procedure and restart
1 – Use the buttons (18) to interrupt the pipe heating cycle, or use the but-
ton (19) to interrupt the socket belling cycle.
– If the heating is interrupted, the pipe is transferred to the socket belling
station and unloaded without being belled.
– If the socket belling cycle is interrupted, the pipe will be immediately un-
loaded.
Important
The interruption of the machining operation relates to a single pipe.
2 – The machine ignores the rejected pipe and restarts the work cycle
from the next one.
Automatic stop for alarm and restart conditions
During the work cycle, some devices control the machine operating phas-
es and, when faults occur, stop the machine in alarm conditions. These
conditions are indicated by the siren (3), by the warning light (2), and by
the operating terminal (4).
To restart the automatic cycle, proceed as follows.
1 – Press the button (12) to deactivate the siren (3). The warning light (2)
will remain ON.
2 – Consult the reports from the operating terminal ("Operating guide",
section "ALARMS") to restore operating conditions.
3 – If necessary stop the production line and, after having normalised the
operating conditions, restart the automatic cycle (see 6.5., section "Acti-
vating the machine in automatic mode").
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4
2
3
18 19
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Stop due to blackout and restart

In the event of a sudden interruption in the electricity supply, the machine
stops in the "pipe standby" position, and the listed conditions arise.
– The haul-off device lifts up.
– The rolling clamps rise.
– The pipe lifting beams lower.
– The E.P. chamber is depressurised.
Caution - Note
The machine remains supplied with water power.
Important
The counted data are NOT saved.
When the electricity returns, the machine does not start. To start it, pro-
ceed as follows.
The button lights up.
Important
If the causes of the arrest call for the entrance of the operator within
the dangerous areas, it is necessary to proceed as indicated in or-
der to ensure adequate safety conditions.
- Stop pipe feeding.
- Turn the main electricity cut-off switch (1) to "O" (OFF) position to
deactivate electricity supply.
- Isolate the machine from all power sources and discharge residual
energy (See 6.6. - "Deactivating the energy sources (machine dis-
connected)").
- Open or remove the safety guards to access the operation area.
2 – After having normalised the operating conditions, check that no tools,
rags or other materials have been left near moving parts..
3 – Close and refit all the previously removed guards.
4 – Restart the machine in "manual" mode (see 6.5., sec. "Activating the
machine in manual mode") or else in automatic mode (see 6.5., sec."Ac-
tivating the machine in automatic mode").
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Arrest due to end of production and restart

1 – Stop pipe feeding.
2 – Wait for the last pipe to be belled, then press the button (14) to stop
the automatic cycle.
4 – Use the manual commands to remove any pipes left inside the ma-
chine.
nected)").
11
14 1
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Normal stop (machine without pipes)

1 – Press the button (14) to stop the automatic cycle.
Important
Manual stop and restart (machine with pipes)

1 – Press the button (14) to stop the automatic cycle.
Important
3 – Use the manual commands to remove any pipes left inside the ma-
chine.
4 – After restoring normal operating conditions, restart the automatic cy-
cle (see 6.5., sec."Activating the machine in automatic mode") or else
stop the machine (see 6.5., sec."Deactivating the electrical power supply
(machine off)").
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6.8. FORMAT CHANGE

The start of the production phase, to process a new pipe format or pro-
duce a different type of socket, requires a series of operations to configure
the machine.
– Positioning the pipe movement units and the nozzles to remove chips,
in order to adapt them to the diameter of the pipe being machined.
– Adjusting the contact pressure between the haul-off and the pipe rolling
device, to adapt them to the weight of the pipe being processed.
– Assembling the heating devices and the socket belling devices (also
known as equipment change operations), to adapt them to the format of
the pipe being processed.
The changes necessary are listed in the following table.
Table 6.2: Format change parameters
Description Identification
Type of machining
Setting of process parameters see terminal "Operating guide"
Setting the length of the pipe heating cycle see 6.9., sec. "Setting the length of pipe to be heated"
Setting the oven carriage stroke (if present) see 6.10., sec. "Setting the oven carriage stroke"
Setting the rigidity of the oven decelerator (only for
see 6.10., sec. "Setting the stiffness of the oven
machine models equipped with an oven stroke
carriage decelerator"
adjustment unit)
Pipe diameter
see 6.11."Assembling the pipe heating unit (boosted
Replacement of oven equipment
air oven)"
Pipe half clamp replacement see 6.12."Assembly of the pipe clamp unit"
Replacement of belling equipment see 6.13."Assembling the belling unit"
Bench positioning see 6.9., sec. "Bench positioning"
Positioning of chips cleaning nozzles see 6.9., sec. "Positioning of chips cleaning nozzles"
Pipe weight
Setting of pipe haul-off pressure see 6.9., sec. "Setting the pressure (haul-off)"
Pipe rolling clamp pressure setting see 6.10., sec. "Setting the pressure (rotating clamp)"
Pipe thickness
Setting pipe heating temperature see terminal "Operating guide"
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6.9. FORMAT CHANGE OF PIPE TRANSFER

UNIT
Setting the length of pipe to be heated
Qt Lr
Zero line
Zero line
The correct position of the pipe for belling purposes is determined on the
basis of an ideal reference line called the "zero line", which coincides with
the position of the rubber stop flange of the E.P. chamber.
The positioning of the pipe for heating is carried out by the haul-off device,
while the final belling position is obtained by the action of the pipe posi-
tioner integrated in the oven. This position is maintained during every pipe
transfer phase in the heating and belling stations, until the belled pipe is
unloaded.
initials key
Lr: length of pipe to be heated
Qty: haul-off position (distance the pipe has to go, after the photocell de-
tects it, to stop in the heating position)
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Bench positioning
Proceed as follows.
1 – Assemble the equipment in the pipe clamp unit (See equipment as-
sembly manual).
2 – Select a pipe (with the same characteristics as the one to be belled)
and position it in line with the belling station, in front of the open pipe
clamps.
4 – Use the commands on the operating terminal and check the position
of the reference index (D) on the graduated scale (B) to adjust the height
of the bench on the basis of the external diameter of the pipe.
5 – Use the commands of the operating terminal to close the pipe
clamp.(A).
6 – Rest the pipe (C) against the pipe clamps (A) and visually check that
the pipe axis is at the same height as the axis of the closed pipe clamps.
7 – Use the commands on the operating terminal to adjust the height of
the bench, so the pipe (C) is perfectly aligned with the pipe clamps (A).
8 – Deactivate the "manual" operating mode.
9 – Remove the pipe remaining inside the machine.
D
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Positioning of chips cleaning nozzles

Proceed as follows.
and position it on the pipe infeed conveyor beneath the haul-off device.
nected)").
5 – Manually adjust the position of the nozzles (E) so that the jets of air
are directed on the rim of the pipe (C).
Important
8 – Remove the pipe remaining inside the machine using the manual con-
trols.
E C
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Setting the pressure (haul-off)

Proceed as follows.
1 – Adjust the height of the bench according to the external pipe diameter.
2 – Stop the machine (see 6.5., sec. "Activating the machine in "0" mode").
3 – Check the pneumatic power supply is enabled.
and position it on the pipe infeed conveyor beneath the haul-off device.
5 – Start the machine in "manual" mode (see6.5., sec. "Activating the ma-
chine in manual mode").
6 – Use the commands on the operating terminal to start the pipe haul-off
phase.
7 – Use the adjuster knob (F) to regulate the pressure shown on the pres-
sure gauge (G).
Important
The pressure must be between 1.5 and 3 bar.
Important
To check whether the pressure has been correctly set, the pipe
must move forward smoothly, without any awkward or jerky move-
ments and without suffering any deformation as a result of exces-
sive pressure.
8 – Use the manual commands to remove the pipe left inside the machine
(refer to the terminal "Operating Guide").
F
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6.10. FORMAT CHANGE OF PIPE HEATING UNIT

Setting the pressure (rotating clamp)
Proceed as follows.
1 – Adjust the height of the bench according to the external pipe diameter.
2 – Stop the machine (see 6.5., sec. "Activating the machine in "0" mode").
3 – Check the pneumatic power supply is enabled.
and position it on the pipe infeed conveyor.
6 – Use the commands of the operating terminal to position the pipe at the
rolling clamp, and then start the pipe rolling phase.
7 – Use the adjuster knob (A) to regulate the pressure shown on the pres-
sure gauge (B).
Important
The pressure must be between 1.5 and 3 bar.
Important
To check whether the pressure has been correctly set, the pipe
must rotate smoothly, without any awkward or jerky movements
and without suffering any deformation as a result of excessive pres-
sure.
8 – Use the manual commands to remove the pipe left inside the machine
(refer to the terminal "Operating Guide").
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A
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Setting the oven carriage stroke

Proceed as follows.
nected)").
3 – Open the guard (C).
4 – Loosen the locking nut (D).
5 – Loosen the stop lever (E) to reduce the stroke (X) of the oven (F), or
vice-versa.
Important
With the stop lever fully tightened, the oven makes its maximum
stroke.
6 – Tighten the locknut (D) when you have completed the operation.
Caution - Note
Before closing the covers and restarting the machine, check that no
tools or other materials have been left near moving parts.
8 – Close the guard (C).
E
X
D
C
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Setting the stiffness of the oven carriage decelerator

The correct adjustment of decelerator rigidity is essential to prevent the
oven carriage from suddenly stopping, as this action could reduce the
lifespan of the oven heating elements.
Important
The stiffness is adjusted by the Manufacturer at an optimal value,
but over time it may be necessary to correct the adjustment.
Proceed as follows.
If the deceleration isn’t effective enough (sudden stop of the carriage,
with collision), turn the graduated knob (G) up to the next number.
The adjustments must be gradual to avoid internal damages to the unit
(for instance, go from 2 to 3, 5 to 6, and not 1 to 4).
Increase the setting until smooth deceleration is achieved and an ac-
ceptable level of noise is perceived when the carriage starts to deceler-
ate or when the carriage is stopped.
If deceleration is too sharp at the start of the stroke, the setting must be
decreased (one unit at a time) on the adjustment knob (G).
C
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Adjusting the position of the motorised oven (optional)

Use the selector (x) to shift forwards/backwards the carriage of the oven.
X
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Adjusting the pipe edge cooler of the boosted air oven

Proceed as explained below:
1 – Stop the machine and discharge the residual energy (see 6.7.,sec.
"Arrest due to end of production and restart").
2 – Remove the guard (A);.
3 – Insert the pipe edge cooler (E) in the oven.
4 – Calculate the position (x) of the cooler (F) as indicated below:
Determine the length (Lr) of the part of pipe to be heated and position
the cooler at 5-10mm from the edge of the pipe (see "Setting the length
of pipe to be heated").
5 – Identify the reference mark relating to position (x).
6 – Adjust the position of the cooler so that the reference mark coincides
with the end of the sliding guide (D1).
7 – Tighten the screws (D).
8 – Connect the water inlet and return pipes and open taps (C).
Important
Before closing the guards, check that there are no tools or other
material in the vicinity of the moving parts.
10 – Restart the machine in "manual" mode to verify proper operation
(see 6.5., sec. "Activating the machine in manual mode").
11 – Adjust the opening of the gates from the operating panel of the bell-
ing machine using the pins (C) (see sec. "Position of the oven gate
(boosted version)").
gates fully open: pins pushed fully inwards.
gates fully closed: pins fully outwards.
The machine is in an operating condition.
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Chapter 6
ABOUT THE USE
C
C
x D
5÷10 mm
D1
Lr
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Chapter 6
ABOUT THE USE
Position of the oven gate (boosted version)

Proceed as explained below:
1 – Stop the machine and discharge the residual energy (see 6.7.,sec.
"Arrest due to end of production and restart").
2 – Remove the guard (A).
3 – Pull or push the pins (C) to determine whether to heat the pipe inter-
nally or externally.
- To heat the pipe more internally, pull the pin.
- To heat the pipe more externally, push the pin.
Important
Before closing the guards, check that there are no tools or other
material in the vicinity of the moving parts.
The machine is in an operating condition.
C
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Chapter 6
ABOUT THE USE
6.11. ASSEMBLING THE PIPE HEATING UNIT

(BOOSTED AIR OVEN)
6.11.1 Preparing for assembly and disassembly
Before beginning to assemble / disassemble the equipment, set the ma-

chine up in the following configuration.
A – Forming carriage backward
B – Pipe clamp open
To prepare the machine as envisaged, proceed as illustrated.
1 – Start the machine in "manual" mode.
2 – Use the operating terminal controls to activate the movements of the
machine parts.
3 – Stop the machine and turn the main cut-off switch to "O" (OFF) to
switch off the electrical power.
4 – Deactivate the pneumatic supply and discharge the residual pneu-
matic energy.
5 – Disable the water supply and discharge the residual water power.
6 – Allow the components of the intervention zone to cool.
7 – Open and/or disassemble the covers to access the pipe heating and
socket belling cycle area.
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Chapter 6
ABOUT THE USE
6.11.2 Assembly and disassembly of the pipe heating equipment
Important
The information provided explains "step by step" all assembly
phases.
Danger - Warning
Make sure the oven temperature is below 50° C before performing
any operation.
When this state has been reached, switch off the machine and per-
form the operation.
The use of protective gloves is compulsory.
Danger - Warning
Risk of scalding.
Screw (D)
Pipe (L)
Diffuser (A) Tap (M)
Pin (F) Pin (F)
Pin (H)
IDM-40027306700.tif
Screw (B) Cooler (C)
Diffuser (E) disc closing (G)
Proceed as follows.
1 – Prepare the machine for the assembly (See ).
2 – Fit the diffuser (A) and fasten it with the screws (B).
3 – Install the cooler (C) and fix it with the screws (D).
UM_100431_01
4 – Install the diffuser (E) and fix it with the pins (F).
5 – Install the disc (G) and fasten with the pin (H).
6 – Connect the pipes (L).
7 – Open the taps (M).
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Chapter 6
ABOUT THE USE
8 – Adjust the position of the cooler (C).

9 – Adjust the position of the gate that determines the flow of air in the ov-
en.
Important
To disassemble, remember it is necessary to repeat all the assem-
bly phases "step-by-step" but in the reverse order.
6.12. ASSEMBLY OF THE PIPE CLAMP UNIT

A – Forming carriage backward
B – Pipe clamp open
To prepare the machine as envisaged, proceed as illustrated.
1 – Start the machine in "manual" mode.
2 – Use the operating terminal controls to activate the movements of the
machine parts.
3 – Stop the machine and turn the main cut-off switch to "O" (OFF) to
4 – Deactivate the pneumatic supply and discharge the residual pneu-
matic energy.
5 – Disable the water supply and discharge the residual water power.
6 – Allow the components of the intervention zone to cool.
7 – Open and/or disassemble the covers to access the pipe heating and
socket belling cycle area.
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Chapter 6
ABOUT THE USE
6.12.2 Pipe clamp assembly and disassembly
Important
phases.
Proceed as follows.
1 – Prepare the machine for assem-
bly (See 6.12.1 - "Preparing for as-
sembly and disassembly").
2 – Select the components (X-A) to
be combined with the half-clamps
(Y) to obtain the diameter corre-
sponding to that of the pipe to be
locked, referring to the Table 6.3
beneath. Y
X
Important
The value corresponding to the
external diameter of the pipe to A Y
be locked is stamped on each
component.
3 – Assemble the components re-
quired for obtaining the diameter
corresponding to the pipe to be X
locked, fixing them with the relative
screws as shown in the figure. A
Important
If the diameter of the pipe is less than 160 mm, begin the assembly
with the pair of reduction elements (X) then continue until you reach
the same diameter as that of the pipe to be locked.
Table 6.3: Component diameters and codes
Pipe diameter (mm) Component Code
Half-clamp + Reduction element +
32 -159 EE121501 + A
Equipment (Y+X+A)
half-clamp + Reduction element
160 EE121501
(Y+X)
161-199 Half-clamp + Equipment (Y+A) A
200 Half-clamp (Y)
Important
To disassemble, remember it is necessary to repeat all the assem-
bly phases "step-by-step" but in the reverse order.
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Chapter 6
ABOUT THE USE
6.13. ASSEMBLING THE BELLING UNIT

Assembly and Disassembly of Belling Carriage Equipment

– Pipe clamp closed.
– Forming carriage backward.
To prepare the machine for one of
the possible configurations, pro-
ceed as shown.
1 – Start the machine in "manual"
mode.
2 – Use the operating terminal con-
trols to activate the movements of
the machine parts.
3 – Stop the machine and turn the
main cut-off switch to (OFF) to
4 – Deactivate the pneumatic sup-
ply and discharge the residual
pneumatic energy.
5 – Disable the water supply and
discharge the residual water pow-
er.
6 – Allow the components of the in-
tervention zone to cool.
7 – Open and/or disassemble the guards to access the belling area.
8 – Check the taps for delivering and draining cooling water from the mandrel are turned off.
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Chapter 6
ABOUT THE USE
6.13.2 Assembly and disassembly of "Smooth mandrel" equipment
Important
phases.
Proceed as follows.
1 – Prepare the machine for the assembly of the forming carriage equip-
ment (See 6.13.1 - "Preparing for assembly and disassembly").
2 – Assemble the mandrel-holder

shaft (E) and fix it with the screws
(F).
Important
The correct assembly of the
equipment is guaranteed by the
special centring dowels.
F
IDM-40027304300.tif
00 tif
3 – Mount the mandrel (G) and fix it
with the screw (H) and relative
washer.
Important
Pay special attention not to dam-
age the external surface of the
mandrel.
Important
To disassemble, remember it is
necessary to repeat all the as-
H
sembly phases "step-by-step"
IDM-40027304400.tif
but in the reverse order.

00 tif
G
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Chapter 6
ABOUT THE USE
6.14. CHECKS DURING USE

While the machine is running, the operator is required to carry out the following checks.
– Make sure that the machine is not fed with faulty pipes.
– Make sure that the pneumatic operating pressure is adequate for proper
operation of the machine (no less than 6 bar).
– Make sure that the flow rate and temperature of the cooling water are
adequate for correct machine operation.
– Make sure that the actual temperature of pipe heating is the same as
the set temperature.
– Check the absorption of the oven heating elements
– Make sure that the quality of the socket meets the desired require-
ments.
Important
If any anomalies are noted during these checks, the operator must
stop the machine in safe conditions and inform the line manager,
who will then take the action necessary to restore normal operating
conditions.
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Chapter 6
ABOUT THE USE
6.15. CHECKING THE THERMAL STATE OF THE

PIPE TO BE BELLED
The thermal status and softening of the pipe end is fundamental for ob-
taining a socket with the required qualitative characteristics.
– The thermal status is determined by the external and internal tempera-
ture, and by the distribution of the temperature along the surface of the
pipe to be belled.
– The softening is a characteristic of the material of which the pipe is
made, and which highlights its dynamic deformability.
For example, PVC softens dynamically at temperatures greater than
80°C (vitreous transition temperature).
The normal temperatures at the end of the heating cycle (measured on
the pipe surface) are in the 90 ÷ 110°C range.
The figure represents, as a guideline, the typical distribution of the final
heating temperature of the smooth mandrel work cycle.
"Smooth mandrel"
belling cycle
T°c
115°
80°
25°
X
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Chapter 6
ABOUT THE USE
6.16. CHECKING THE TEMPERATURE OF THE

BELLED PIPE
The newly belled socket must have an internal and external surface tem-
perature no higher than 50°C (the temperature is usually 35-45°C).
When the pipe is being cooled down to ambient temperature, the socket
diameter shrinks.
– If there is a notable difference between the temperature of the pipe at
the end of the work, and the ambient temperature, the socket diameter
will shrink even more.
– If the difference between the temperature of the pipe at the end of the
work, and the ambient temperature, is near zero then the socket diame-
ter will shrink less.
When you need to work pipes with a new format and/or a new ma-
terial mixture, it may be a good idea to check the thermal status of
the newly belled socket.
The temperature check must be carried out with a portable infra-red ther-
mometer after the pipe has been unloaded from the machine.
Caution - Note
During these operations, the pipe to be checked must be locked on
a horizontal plane and the operator must wear the protective gloves
supplied.
6.17. CHECKING SOCKET DIMENSIONS

The size checks (socket diameter, dimensions of the gasket seat, etc.)
must be carried out when the socket temperature is about 21-25°C.
UM_100431_01
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Chapter 7
INFORMATION RELATING TO MAINTENANCE 7
7.1. RECOMMENDATIONS FOR

MAINTENANCE
Important
Before carrying out any maintenance work, activate all safety devic-
es and, if necessary, inform all personnel working in the vicinity of
the machine. In particular, identify the surround areas with appro-
priate signs and impede access to all devices which could cause
conditions of unforeseen danger or risks to health and safety if ac-
tivated.
7.2. ROUTINE MAINTENANCE
Important
Keep the machine in maximum efficiency conditions and perform
all the scheduled maintenance operations provided by the manu-
facturer. Good maintenance will result in better performance, a
longer operating life and keep the safety requirements unchanged
over time.
Table 7.1: Routine maintenance intervals

Frequency
Component Inspection Action
24h 150h 500h
Pneumatic system
Clean (see "Maintenance sheet

Check cleaning ■
MR89").
Filter/Regulator Unit
Drain (see "Maintenance sheet
Check condensation ■
MR89").
Drain (see 7.4. - "Draining of air

Air storage tank Check condensation ■
tank condensate").
Adjust (see "Maintenance sheet

Operating pressure Check the value ■
MR89").
Water system
Drain (see "Exchanger draining

Heat exchanger Check condensation ■
condensate").
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Chapter 7
INFORMATION RELATING TO MAINTENANCE

Frequency
24h 150h 500h
Electrical system
Photocells Check cleaning ■ Clean with a soft, damp cloth.
Clean the magnetic strip with a

Encoder Check cleaning ■
soft cloth moistened with water.
Pipe haul-off device
Replace (See 9.4. - "Replacing

Wheels Check for wear ■
haul-off wheels").
Stretch (See 5.3. - "Drive chain

Check tension ■
adjustment (haul-off)").
Drive chain
Lubricate with grease (See 7.6. -
Check lubrication ■
"Chart of lubrication points").
Rolling clamp
Check the state of Replace (see 9.5. - "Replacing

Drive ■
wear of the rollers the rotating clamp rollers")
Pipe clamp

Slide guides Check lubrication ■
Forming carriage
Lubricate with grease (see "Main-

Movement actuator Check lubrication ■
tenance sheet MR091").

Slide guides Check lubrication ■
Top up if necessary (see "Mainte-

Lubricator filter Check oil level ■
nance sheet - MR89")
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Chapter 7

Frequency
24h 150h 500h
Pipe transfer bench
Bench height adjustment Lubricate with grease (See 7.6. -

command "Chart of lubrication points").

Drive chains
Stretch (See 5.2. - "Adjusting the
Check tension ■
chain (bench)").

Gears and racks Check lubrication ■
Replace, if necessary (See 9.2. -

Pipe support rollers Check for wear ■ "Replacing the rollers and pipe
support wheels").
Boosted air oven
Replace (see "Maintenance

Heating element Check efficiency ■
sheet MR12").
Threaded bar for moving the Lubricate with grease (See 7.6. -
pipe positioner (if present) "Chart of lubrication points").
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Chapter 7
7.3. CLEANING THE MACHINE

Proceed as follows.
nected)").
3 – Open or disassemble the guards around the work zone.
4 – Clean the surface of the rollers of the rotating clamps (A), and the
wheels (B) of the haul-off device, using a cloth moistened with water and
a suitable detergent.
5 – Clean the photocells (C) using a cloth moistened with water and a
suitable detergent. To identify the position of the photocells, see para-
graph 2.10. - "Electric devices".
Important
Before closing the covers and restarting the machine, check that no
tools or other materials have been left near moving parts.
6 – Reassemble the guards.
C
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Chapter 7
7.4. DRAINING OF AIR TANK CONDENSATE

Proceed as follows.
1 – Prepare an appropriately sized container.
2 – Open the tap (A) to drain the condensate from the tanks (A1-A2).
3 – Let the water flow through the container.
4 – Close the tap (A) again.
A1 A2
A
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Chapter 7
7.5. EXCHANGER DRAINING CONDENSATE

Proceed as follows.
1 – Prepare an appropriately sized container.
2 – Open the tap (B) to drain the condensate from the collection tank of
the heat exchanger (B1).
3 – Let the water flow through the container.
4 – Close tap (B).
B1
B
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Chapter 7
7.6. CHART OF LUBRICATION POINTS

Lubricate the components illustrated with the methods described at the
intervals indicated.
Important
Use oil with the same characteristics as those indicated in the "Lu-
bricants table" (see page 139).
Bench - Pipe clamp - Belling unit
500 h
150 h
150 h
500 h
Key
Cover with grease Inject grease
Important
To lubricate the belling unit, see "Maintenance Sheet MR091".
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Chapter 7
Conveyor - Pipe haul-off device
150 h
150 h
Key
Cover with grease Inject grease
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Chapter 7
7.7. LUBRICANTS TABLE
Table 7.2: Lubricants characteristics (oil)

Component Quantity Specifications (Manufacturer - Type)
AGIP ACER MV 10
Mandrel
SHELL MORLINA S2 BL 10
segment 125 cm³
TEXACO RANDO HD 10
lubricator
CHEVRON SPINDE OIL 10X
Important
The machine is delivered without the quantities of oil required. For
filling, comply with the table. The pneumatic system lubricator filter
is pre-calibrated for optimum lubrication, so the oil level must be
kept constant to prevent malfunction.
Danger - Warning
Do not mix oils of different manufacturers, or oils with different
characteristics.
Table 7.3: Lubricants characteristics (grease)

Component Specifications (Manufacturer - Type)
TEXACO GREASE L EP1
IP ATHESIA GREASE 1
AGIP GR MU EP 1
API GREASE PGX-1
Greasers, chains, BP GREASE LTX 1
guides and sliding ESSO BEACON EP 1
surfaces FINA MARSON EPL 1
MOBIL UX P1
ROLOIL LITEX EP 1
SHELL ALVANIA EP GREASE 1
TOTAL MULTIS
Actuator for
moving the forming MOBIL MOBILUX EP004
carriage
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Chapter 7

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Chapter 8
TROUBLESHOOTING 8
8.1. MALFUNCTIONS
The machine is designed to automatically signal the main malfunctions
possible during operation, via alarm messages that can be viewed on the
operating terminal. As this is an automatic machine, the operating cycle
consists of sequence of actions, with each action receiving consent from
the previous action and providing consent for the next. As a result, when
the operating cycle is interrupted, the last action performed which failed
to provide consent for the next may be identified.
Danger - Warning
Before performing any work on the machine, consult the "Diagnos-
tics" section of the terminal "Operating guide".
The following table lists a number of general problems and malfunctions.
Table 8.1: Machine malfunctions
Problems Cause Remedy
Overhaul the actuator (see
A pneumatic actuator is Actuator fault
"Maintenance sheet MR21")
showing a partial or total loss
of efficiency Overhaul the solenoid valve (see
Solenoid valve fault
Magnetothermal circuit breaker
Allow the electric motor to cool and reset
An electric motor is not has cut off the power supply to
the circuit breaker
working prevent motor burnout
Electric motor fault Replace electric motor
Height of pipe transfer bench Adjust the bench height (see 6.9., sec.
The pipe haul-off device is not incorrect "Bench positioning")
transferring the pipe Insufficient presser operating Adjust the operating pressure (see 6.9.,
pressure sec. "Setting the pressure (haul-off)")
Tighten the chain (see 5.3. - "Drive chain
The drive belt is slack
adjustment (haul-off)")
The haul-off device transfers Replace the chain (see 9.3. - "Replacing
Worn drive chain
the pipe in a jolting manner the haul-off drive chain")
Clean and replace if necessary (see 9.4.
Wheels worn or dirty
- "Replacing haul-off wheels")
The set temperature value is Reduce the pipe heating temperature
excessive (refer to the terminal "Operating Guide")
The temperature regulator is
Replace
The boosted air oven does not faulty
reach the set temperature Replace the heating element (see
Faulty heating element
"Maintenance sheet AF3.1/MR12.1")
Replace the thermocouple (see
Thermocouple failure
The stop of the oven The damper devices of the oven
Adjust the actuator damper devices (see
UM_100431_01
advancement is too abrupt or carriage pneumatic actuator are

slow not suitably adjusted
- 141 -
Chapter 8
TROUBLESHOOTING
Table 8.1: Machine malfunctions

incorrect "Bench positioning")
The rolling clamp does not
Insufficient presser operating
turn the pipe Adjust the operating pressure
pressure
Elliptical pipe Change the pipe
The rolling clamp turns the Pipe surface lubricated too much Change the pipe
pipe in a jerking manner Rollers worn or soiled Clean and change if necessary
Assemble the half-collars and suitable
Clamp elements unsuitable for
The clamp does not block the pipe diameter reducers (See equipment assembly
pipe during belling manual)
Worn or damaged rubber seal Replace
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Chapter 8
TROUBLESHOOTING
Table 8.2: Malfunctions

Set the production parameters by means
Production parameters not
of the operating terminal (refer to the
suitable for pipe characteristics
The pipe is not machined terminal "Operating Guide")
incorrect "Bench positioning")
Pipe heating temperature too Reduce the heating temperature (refer to
high the terminal "Operating Guide")
Inner diameter of the socket is Shorten the heating time (see terminal
Pipe heating time too long
too narrow "Operating guide")
Increase the cooling time (see terminal
Inadequate socket cooling
"Operating guide")
Pipe heating temperature Increase the heating temperature (see
insufficient the terminal "Operating Guide")
Inner diameter of the socket is Increase the heating time (see terminal
Pipe heating time too short
too wide "Operating guide")
Decrease the cooling time (see terminal
Socket cooling time too long
"Operating guide")
Forming of wrinkles on the high the terminal "Operating Guide")
surface of the pipe Shorten the heating time (see terminal
"Operating guide")
Pipe heating temperature Increase the heating temperature (see
insufficient the terminal "Operating Guide")
Socket surface is irregular
Increase the heating time (see terminal
Pipe heating time too short
"Operating guide")
Socket rim burnt or with signs high the terminal "Operating Guide")
of melting Shorten the heating time (see terminal
"Operating guide")
UM_100431_01
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Chapter 8
TROUBLESHOOTING
UM_100431_01
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Chapter 9
INFORMATION ON SPARE PARTS 9
9.1. RECOMMENDATIONS FOR REPLACING

PARTS
Important
Before carrying out any replacement work, activate all safety devic-
es and, if necessary, inform all personnel working in the vicinity of
the machine. In particular, identify the surround areas with appro-
priate signs and impede access to all devices which could cause
conditions of unforeseen danger or risks to health and safety if ac-
tivated. When replacing worn parts, use only original replacement
parts. The manufacturer cannot be held responsible in the event of
injury, or damage to property, caused by the use of non-original
spare parts or repairs performed without authorisation from the
manufacturer. To request spare parts follow the instructions in the
spare parts catalogue.
All replacement and repair work must be performed with machine
disconnected from all power sources and following the instructions
given by the manufacturer. In the event of procedures not described
in the manual, contact the Support Service for instructions.
UM_100431_01
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Chapter 9
INFORMATION ON SPARE PARTS
9.2. REPLACING THE ROLLERS AND PIPE

SUPPORT WHEELS
Proceed as follows.
energy (see 6.5., sec. "Deactivating the electrical power supply (machine
off)").
3 – Disassemble the guard that prevents access to the intervention area
(A).
To replace the rollers (C), proceed as follows.

1 – Remove the screws (B).
2 – Disassemble the roller (C) and replace it with a new one.
3 – Tighten the screws (B) when you have completed the operation.
To replace the rollers (E), proceed as follows.

1 – Remove the snap ring (D).
2 – Extract the roller (E) and replace it with a new one.
3 – Put back the snap ring (D) when the operation is finished.
To replace the rollers (G), proceed as follows.

1 – Unscrew the screws (F).
2 – To make the operation easier, raise the supports (H), take out the roll-
er (G) and replace it with a new one.
3 – Position the supports at the holes on the bench and tighten the screws
(F) when the operation is finished.
Caution - Note
4 – Re-fit guard (A).
UM_100431_01
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Chapter 9
A
B
G E
D
H H
235180067-00
UM_100431_01
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Chapter 9
9.3. REPLACING THE HAUL-OFF DRIVE CHAIN

Proceed as follows.
nected)").
4 – Use the screw (B) and counter nut to raise the tensioner (C) and
slacken the tension of the belt.
5 – Pull out the joining link (D) and disconnect the chain.
6 – Fit the new chain and fix it with the joining link.
7 – Press the tensioner (C) towards the chain to tension it and tighten the
screw (B).
Caution - Note
B C
D
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Chapter 9
9.4. REPLACING HAUL-OFF WHEELS

Proceed as follows.
nected)").
4 – Loosen the grub screw (B).
5 – Unscrew the screw (C) and remove the encoder unit (D).
6 – Unscrew the nuts (E) and the screw (F).
7 – Dismantle the wheels (G-H) and replace them with new ones.
8 – Tighten the screw (F) and the nuts (E).
9 – Reinsert the encoder unit (D), tighten the screw (C) and the grub
screw (B).
Caution - Note
11 – Restart the machine in "manual" mode to verify proper operation
(see 6.5., sec. "Activating the machine in manual mode").
E
G
C
D F
H
B
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Chapter 9
9.5. REPLACING THE ROTATING CLAMP

ROLLERS
Proceed as follows.
nected)").
4 – Loosen the nuts (B).
5 – Loosen the grub screws (C) and take out the pin (D).
6 – Replace the roller (E) and reinsert the pin (D).
7 – Tighten the grub screws (C) and the nuts (B).
Caution - Note
B
C
E C A
B
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Chapter 9
9.6. MACHINE DECOMMISSIONING

– When decommissioning the machine, take all measures necessary to
ensure that the machine and its components do not constitute a hazard
and are not accessible by unauthorised persons.
– To ensure that the machine does not constitute a hazard to persons or
the environment, disconnect all power sources (electric, pneumatic, etc.)
and render them unusable, and drain any remaining fluids (lubricants,
etc.).
– Keep the machine in a dedicated area that is appropriately delimited to
prevent unauthorised access.
9.7. MACHINE DEMOLITION

– The person or persons authorised to scrap the machine must, if neces-
sary, produce a "safety plan" to ensure the safety of all persons directly
involved and ensure strict observance of all applicable legislation con-
cerning the workplace and mobile work sites.
– Disassemble all the main parts of the machine. For more detailed infor-
mation, contact the manufacturer's technical support service.
– When scrapping the machine, group components by chemical compo-
sition and dispose of separately in accordance with applicable legislation.
– Do not dispose of non-biodegradable materials, lubricant oils and non-
ferrous articles (rubber, PVC, plastics etc.) in the environment. Dispose
of them correctly, in compliance with applicable legislation.
UM_100431_01
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Chapter 9

UM_100431_01
- 152 -
MAINTENANCE SHEETS
Sheet N° Title
MR2 PNEUMATIC SOLENOIDS
MR4 QUICK DISCHARGE
MR6 THERMOCOUPLES
MR11 HEAT EXCHANGER
MR12 HEATING OVENS
MR19 PRESSURE ACCUMULATOR
MR21 PNEUMATIC CYLINDERS (bore from Ø 32 to Ø 125)
MR89 FILTER GROUP- PRESSURE REGULATOR

LUBRICATOR - COMPRESSED AIR TAP
MR91 ISOMOVE MECHANICAL ACTUATOR
Certain components shown in the illustrations may differ from those in the User's possession. This does not however
compromise the sequence of the assembly instructions.
ATTACHMENTS
maintenance card relevant to:
Pneumatic solenoid valves

MR
2 Rev.01
Danger - Warning
Required machine status: INSULATED AGAINST ALL POWER
SOURCES.
Operation to be performed ONLY by the maintenance engineer.
Danger - Warning
Moreover, it is necessary to consider the movements of any
componentwhich is not held by the oil pressure in the relevant
cylinder any longer.
They can be manually actuated (without electric excitation) by pressing

on the impulse control device (a) using a not-pointed tool.
Coil (1)
Replace it when, even if excited, it does not perform the movement
required any longer.
Unscrew the screws (b) and take out the reel.
Valve (2)
It has to be removed if performing no longer its airproof function.
Disassemble the valve body (2) by means of the screws (c).
In case of replacement, be careful when mounting gasket (3).
The positioning of the valve in the housing is assured by the stop
lever (d) which should be inserted in the hole (e).
Secure the solenoid valve (2) by tightening the screw (c) with a tightening
torque of 2.5 Nm.
1 - Coil
2 - Valve
3 - Seal
a
d
a
e 3 2
c
1
MR2 - 1
DUMP VALVE
MR
4
Required machine status: INSULATED AGAINST ALL POWER SOURCES.
Replace gasket (1) when the dump valve is losing its efficiency.
Disassemble gasket (1) after removing cap (2).
961
95.0
3
THERMOCOUPLES
MR
6
N.B. Replace the thermocouples in case of any malfunctioning.
Thermocouple (1) is to be fitted inside support (a). Lock it through coupling (b).
Electric wire (c) should be let sufficiently free to follow the movements of the components on which the
thermocouple is mounted.
WARNING
Never shorten the electric wire!
The electric wire shortening could hinder the thermocouple setting.
Connect the electric wire directly to the thermoregulator by means of wire terminals (d).
Should the wire be too long, wind it up so to form a skein and fix it inside the electrical control panel.
b
d
9619
5.04
HEAT EXCHANGER
MR
11
Should the system remain idle, even for a period of less than two months, drain the water from the exchanger.
The water side of the exchanger should be cleaned at least every six months. Change the water filter after each
clean. Should the system be left idle in ambient temperatures below 0 °C it is recommended that all the water
be drained from the exchanger to prevent internal freezing and consequent pipe bundle bursts.
Check the anode (1) periodically: do this by removing the screw (a) and check for zinc exhaustion. In case of
extensive erosion change the anode.
WARNING
Galvanic currents may severely damage the metal structure.
Therefore always check the level of wear on the anode (1).
Periodically check the flow of cooling water by disconnecting the rubber discharge hose. Should interior pipes
require cleaning dismantle the two side covers (b-c) and clean the pipe bundle (d) with anti-limescale liquid
or a 10% hydrochloric acid solution.
If necessary, contact a company specialized in the maintenance of car radiators.
Limescale deposits inside the pipe bundle reduce heat exchanger efficiency.
The exchanger should be replaced when leaking occurs or when water infiltrates inside the power plant.
COOLING WATER CHARACTERISTICS
Observe the following rules:

- do not use brackish water;
- water must be between PH 5 and 9;
- fit a filter at the water infeed point wherever water is dirty or hard;
- water speed inside the exchanger must never exceed 3 m/sec.
96195.08
b
1
a
HEATING OVENS
MR
12
WARNING
Before carrying out any operation make sure that the oven temperature, as indicated on the ther-
moregulators, is below 50°C. When this condition is reached work with the machine off.
Always wear the protective gloves.
DANGER
Risk of serious burns !
IMPORTANT
We advise you to keep the fan working for quicker cooling.
HEATING ELEMENTS (1)

In some oven models they should be disassembled after removing basket (2) (*). In other models, they should
be disassembled by removing rear support (3) (•).
FANS (4)
In some oven models they should be disassembled after removing basket (2) (/). In other models, they should
be disassembled after removing rear flange (5) (•).
(*): BA/NSP 1T 32-200, BA/NSPL 1T 32-200, BA/NS 1T 32-200

BA/NSL 1T 32-200, BA/CA 1T 50-250, BA/CAL 1T 50-250
(/): (*) + BA/CA 1T 100-500, BA/CA 1T 110-630, BA/CA 1T 110-800
(•): all the other models
5
96644.14
2
96644.15
3
1
4
MR HEATING OVENS
12
BELTS (6)
In some oven models it is necessary to stretch belt (6). Adjust nuts (7); the belt should present a 4 mm deflection
for each side.
4 6
2 7
4.10
9664
4.11
9664
1
2
966
44.
12
1
2
96
64
4.
13
PRESSURE ACCUMULATOR
MR
19
Check the accumulator during the first week of system operation. if there are no leaks the following checks can
be carried out about every three weeks.
Accumulator pre-loading check

An approximate method for checking pre-loading is as follows:
- with the system at pressure and the accumulator loaded, stop the pump;
- slowly unload the accumulator fluid by opening the discharge cock; monitor the pressure on the delivery
pressure gauge;
- when accumulator pre-loading pressure is reached (inflation pressure) the gauge needle suddenly drops to
zero;
- the inflation pressure corresponds to the reading the instant before the needle drops to zero.
To ensure proper accumulator operation pre-loading pressure must be kept constant; it must be periodically
checked and must correspond with the figure on the machine hydraulic diagram.
DANGER
The accumulators must only be pre-loaded with nitrogen.
Never use air or oxygen!
Checking pre-loading
This task must be performed correctly as follows, using the pre-load instrument in the figure:
- disconnect the accumulator from the system and drain the contained fluid;
- remove the gas valve and inflation valve protection plugs;
96619.146
MR PRESSURE ACCUMULATOR
19
- before assembling the apparatus make sure that the knob (1) is unscrewed, that the vent (2) is closed, that
the hood on the check valve (3) is screwed on;
- use the knurled crown (4) to screw the instrument onto the gas valve;
- screw on, but don’t force, the knob (1) until a pressure reading is obtained.
If the value corresponds with the prescribed one, disassemble the instrument: after first unscrewing the knob
(1) as far as its limit stop and opening the vent (2), undo the crown (4).
IMPORTANT
To modify the pre-loading value contact specialized personnel.
Should the unit remain idle for more than two months release the nitrogen from the accumulator.
DANGER
Danger of explosion! The accumulators are loaded with pressurized gas.
If they are to be SCRAPPED they must be COMPLETELY UNLOADED first.
2
3
4
96619.146
MR
maintenance sheet for:
PNEUMATIC CYLINDERS (bore from Ø 32 to Ø 125)

(bore from Ø 160 a Ø 200 round sleeve)
21
Rev. 03
Machine prescribed state: Isolated from all energy sources;
DISCHARGED FROM RESIDUAL PNEUMATIC POWER.
Operation carried out EXCLUSIVELY by the maintenance engineer.
Replacing the gaskets

Replace air cylinder seals when movements become irregular and noise
levels increase or the piston rod shows signs of sticking.
To replace, remove the heads (1-2) from the sleeve (3):
4
-for models with a bore of Ø 32 to
Ø 125 unscrew the eight "pulling"
screws (4)
-for models with a bore of Ø 160 to Ø 1 4
200 unscrew the nuts (5) and remove
the tie-rods (6).
Follow the indications in the illustration,

the seals to be changed are shown in 2
the following section views.
3
Ø32 - Ø125
1 5
2
Ø160 - Ø200
MR21 - 1
MR
Pneumatic cylinders (bore from Ø 32 to Ø 125)
21
Rev. 03

List of seals
1 - STEM SEAL Ø32 - Ø125
(polyurethane or NBR);
2 - CUSHIONING SEAL 2 4 3
3 - STRIKE PAD (NBR);
4 - PISTON SEAL
5 - WATERTIGHT SEAL
INSIDE THE PISTON;
6 - CUSHIONING PIN
SEAL (internal);
7 - CUSHIONING PIN
SEAL (external); 1 5
8 - GUIDE CONVEYOR
(technopolymer)
Seal (2) is not present in single-acting
cylinders. Ø160 - Ø200 2 8 4 6 7
MR21 - 2
MR
21 Rev. 03
Check the fastening of the magnetic sensors

Depending on the type of the cylinders installed and the bore the magnetic sensor fixing can be:
-- hidden: the magnetic sensors (S) slide in a guide in the cylinder sleeve, secured using special screws
(Metalwork "series 3" or "type A" cylinders, Univer series "KD-" cylinders, bore from Ø 32 to Ø 125);
-- using a clamp or bracket: the magnetic sensors (S) are fixed to the sleeve of the cylinder using the clamp
(A) or the bracket (B) (Univer series "K-" cylinders, with bore from Ø 32 to Ø 125 and all models with a
bore from Ø 160 to Ø 200).
Check fastening of the magnetic sensor every 500 hours of continuous operation and, if necessary, place
them back in the correct working position.
Switches incorrectly fastened or placed cause irregularities in the automatic operation cycle.
Sensors fixed using a clamp or a bracket
"Hidden" sensors
MR21 - 3
MR
21
Rev. 03
Adjusting the pneumatic actuator

dampers
The pneumatic actuators are equipped with "damper" devices to lower the
movement near the travel limit.
Important
The device is properly adjusted by the manufacturer during testing
and must not be tampered with.
For adjustment, proceed as follows. 1

1 – Stop the machine and turn the
main cut-off switch to "O" (OFF)
to switch off the electrical power.
2 – Isolate the machine from all
energy sources and discharge
the residual energy (See
"machine isolated from energy
sources").
3 – Open and disassemble the
access guards to the work zone.
4 – To increase or decrease the
braking force, tighten or loosen
the screw (1).
Important
Before closing the covers and restarting the machine, check that
5 – Reassemble the guards.

6 – Restart the machine in "manual" mode to check the correct operation
(See "Machine ON in "MAN"" mode).
MR21 - 4
Filter unit - Lubricator pressure

MR
regulator - Holding valve 089
Rev.02
The treatment of the compressed air is necessary to attain the requisites

required by the appliances installed in the machine’s pneumatic system.
The operations for treating the compressed air consist of filter with
varying degrees of thrust, both in the reduction and stabilisation of the
pressure, as well as, in certain cases, in the addition of lubrication oil
in precise quantities.
In the general configuration of the pneumatic system, the air treatment
units are located upstream of the pneumatic appliances and are composed
of modular elements that can be present in one or more units and that
can be integrated with auxiliary elements, like the sectioning valve
(electric or manual control), the gradual starter and the connector blocks.
This maintenance sheet concerns the components Bosch Rexroth

of the AS series (in particular AS2 / AS3 / AS5).
Important
All the activities related to the maintenance and adjustment of
the components that are the subject of this maintenance sheet
require basic mechanical, electrical and pneumatic knowledge,
as well as understanding of the relative technical terms.
To ensure safety, these operations should therefore only be carried
out by specialists in the area or by a trained person under the
guidance and supervision of qualified personnel.
By specialist personnel, we mean those who, thanks to their
professional training, their knowledge and experience and
understanding of the regulations in force, are capable of evaluating
the work commissioned, identify the possible dangers and adopt
adequate safety measures.
Danger - Warning
Unless otherwise specified, the required machine status: isolated
from all energy sources.
Important
These components can be mounted on the machine in numbers
and configurations different from that illustrated.
For the purposes of use and maintenance, the following instructions
should in any case be followed.
MR089 - 1
MR maintenance card relevant to:

089
Rev.02
regulator - Holding valve
Holding valve
This is a monostable 3/2 valve assembly with manual operation, which
allows you to stop the operation of the appliances by discharging the
pneumatic line.
it is an indispensable component for isolating the system in the event
of a breakdown or for maintenance.
Adjusting the position of the valve

In the position (a) the lockout valve 3/2 is open (III).
–– To block the pressure, rotate the knob 90° clockwise.
In position (b) the pressure P1 is blocked and the pressure P2 is
discharged.
Closing the valve

To avoid an unauthorised opening of the lockout valve 3/2, the knob
can be locked with a padlock (IV).
1. Remove the retainer plate (a).
2. Only for AS2:
Push the membrane hinge downwards.
3. Attach the padlock (it is possible to use up to three padlocks).
MR089 - 2

MR
Rev.02
Cleaning and care

–– Close all the openings with suitable safety devices to prevent
detergents entering the system.
–– Never use aggressive detergents or solvents.
Clean the product only with a slightly damp cloth.
Only use water and a delicate detergent if necessary.
–– Do not use high pressure washers for cleaning.
–– Do not use compressed air for cleaning (blowing) the unit.
MR089 - 3

089
Rev.02
Filter
Captures and eliminates the impurities in the compressed air coming
from the supply line, like dust, oil and water, in order to protect the
pneumatic components installed in the system.
In fact, these impurities, speed up the wear of the pneumatic components,
forming build-up that damage especially the gaskets, and as a result
causing leakages and power loss.
Filter cleaning
The discharge of the condensate can be of the type:
–– Manual
–– Semiautomatic
–– Automatic
Manual discharge of the condensate

The condensate (b=lower edge of the
filter cartridge) can also be discharged
manually.
1. Turn the drain screw (a) to the left.
Semi-automatic draining of the condensate
Danger - Warning
Possible damage of the compressed air system caused by
condensate!
With the semi-automatic discharge of the condensate, the
condensate is released only if the container has no pressure.
In the event of extended running, the condensate can exceed
the maximum level and finish up in the compressed air system,
damaging it.
–– Regularly check the filling level of the collection container.
–– Drain the condensate manually if it has reached the maximum
filling level. The maximum level of the condensate water is
indicated by the notch on the tank itself.
Never exceed this level.
–– Do not drain the condensate into the environment in an
uncontrolled way.
The semi-automatic discharge of the condensate closes with a pressure

greater than 1,5 bar and opens with an operating pressure less than
1,5 bar.
MR089 - 4

MR
Rev.02
Adjustment of the automatic operation

Turn the discharge screw completely
to the left.
The screw can remain in the threading
with one turn or else can be completely
removed.
Manual discharge of the condensate

The condensate can also be drained
manually. a
1. Turn the discharge screw (a)
completely to the right (closed)
2. Turn the discharge screw (a) a few
turns to the left until the condensate
comes out.
Automatic discharge of the condensate
“Normally open” implementation

With the “Normally open” implementation the draining of the condensate
closes with a pressure greater than 1,5 bar and opens with an operating
pressure less than 1,5 bar.
The valve opens automatically as soon as the float reaches its maximum
point and closes when the float reaches the lowest point.
Adjustment of the automatic operation

Turn the draining screw completely to the right as far as it will go.
The screw can remain in the threading with one turn or else can be
completely removed.
“Normally closed” implementation

The draining of the condensate is closed independently of the operating
pressure.
The valve opens automatically as soon as the float reaches its maximum
point and closes when the float reaches the lowest point.
MR089 - 5

089
Rev.02
Maintenance / Cleaning the filter

Keep to the following instructions:
Use only a slightly damp cloth.
To this end only use water and a delicate detergent if necessary.
Replacing the filter element

Over time the filters clog up, so they need replacing regularly:
–– Filters with a dirt indicator
the red mark indicates when it needs
replacing.
–– Filters without a dirt indicator
For the active carbon filter, six
months; all other filters, annually.
However, these are only indicative,
since the intervals depend on the
quality of the compressed air and
the air flow rate.
To replace the filter element, proceed
as follows:
1. Pull the release (a) downwards, turn
the container (b) first left and then
remove it from the bottom (c).
2. Unscrew the filter (d, e).
3. Remove the top adjustment valve.
4. Replace the filter cartridge (f).
5. Assemble the adjustment valve in
the correct position.
6. Screw in the new filter cartridge (g)
and gently tighten it by hand (h).
7. Insert the container rotated 45° (i)
and rotate it right until the release
audibly unlocks in position (j).
MR089 - 6

MR
Rev.02
Disposal
Dispose of the product and the hydraulic liquid in compliance with the
laws in force in your Country.
Troubleshooting
Problem Possible cause Remedy

Dirty filter. Clean or replace the filter.
The pressure/flow level is not
reached or slowly diminishes
The filter is too small. Select a larger filter.
The maximum permissible pressure, the temperature range and the
type of threaded coupling are indicated on the component.
MR089 - 7

089
Rev.02
Pressure regulator - Reducing valve

There are pressure variations in the distribution lines of the
pneumatic system, even quite large variations, which, if they have
repercussions on the pneumatic appliances, can cause irregular
and variable running.
The pressure reducer/regulator has the twin function of reducing the
input pressure to a value suited to the user’s requirements and to keep
this value constant.
Assembling the pressure gauge

1. Screw in the pressure gauge to
be assembled in the pressure
gauge thread until the gasket
is completely screwed onto the
threading (Spanner from 14).
Tightening torque Max: 7÷8 Nm
2. Adjust the pressure gauge with Max.
3/4 turn forwards or Backwards.
Setting the pressure
Important
The operation should be carried out with the machine powered
by pneumatic energy.
1. Pull the hand-wheel (a) upwards.

2. Set the desired pressure by turning the hand-wheel (a).
3. Push the hand-wheel (d) downwards.
The hand-wheel is blocked again.
It is possible to read the pressure value on the (d) pressure gauge.
P2 - Outlet pressure
(regulated)
P1 - Inlet pressure
(not regulated)
MR089 - 8

MR
Rev.02
Closing the pressure reduction valve

–– Turn the top crown of the hand-wheel towards the right, until the
safety slits are completely closed.
Blocking the hand-wheel

To prevent an arbitrary modification of the pressure setting, protect the
hand-wheel of the pressure reduction valve with a padlock.
Proceed as described below:
1. Push the hand-wheel (a) downwards.
2. Turn the top crown (b) of the hand-
wheel left to the locking position.
The safety slits (c) are extracted.
3. Attach the padlock to one of the
safety slits (c) and close it.
Pressure regulator filter

It integrates, in a single module, the
filter (f) and the pressure regulator with
g
a pressure gauge (g).
Caution - Warning
For the adjustment and maintenance procedures, see the previous
chapters regarding the filter and the pressure regulator-reducer
respectively.
MR089 - 9

089
Rev.02
Lubricator
The lubricator is located downstream of the filters and the pressure
reducers/regulators and it is vital to make sure that the compressed
air contains a certain amount of oil for all those appliances that need
it to operate correctly.
The function of the lubricator, then, is to add an amount of oil in the
form of small drops drawn by the air that crosses the component.
It is indispensable to regularly check the oil level in the tank, which
should be kept at the level notch (MAX) on the tank.
Filling the oil tank manually

Top up the oil if its oil level has reached the lower edge of the large
control window (a).
Danger - Warning
it is forbidden to fill up with oil
while the machine is running.
Discharge the air from the machine’s
system before unscrewing the tank.
Proceed as follows:
1. Remove the oil tank from the
maintenance appliance.
2. Fill the tank with the appropriate
oil (see “Technical specifications”)
until the oil can be seen in the small
control window (b).
Caution - Warning
If too much oil is put in, the oil could leak into the system and
damage it.
3. Insert the oil tank into the maintenance appliance until the lock
audibly clicks into position.
MR089 - 10

MR
Rev.02
The semi-automatic filling of the oil tank

1. Connect the oil pipe to the tank
coupling (a) and immerse it into
a tank with the specific oil (see
“Technical specifications”).
2. Press the button to fill with oil (c)
until the oil has reached the small
control window (b).
Setting the amount of oil

1. Adjust the amount of oil with the
dosing screw on the lubricator
collection vessel.
The number of drops are reduced
by turning clockwise, and increased
by turning counterclockwise; falling
drops are visible in the tank (f).
2. Fix the amount of oil dispensed by
observing the number of drops in
the collection vessel.
Indicative value (qv = 1000 Nl/1’):
1÷2 drops/min.
f
Cleaning and care

Clean the product only with a slightly damp cloth.
Only use water and a delicate detergent if necessary.
MR089 - 11

089
Rev.02
Troubleshooting
Problem Possible cause Remedy

The oil does not reach the Min filling
Top up the oil in the container.
level in the tank.
Oil content in the compressed
Dosage too low. Increase the number of drops.
air is too low
Ambient temperature is lower than
Use low viscosity oil.
that set for that moment.
A quantity of oil has been put into
Empty out the oil until it reaches
the tank that goes beyond the Max
the Max filling level.
Oil content in the compressed filling level.
air is too high Dosage too high. Reduce the number of drops.
Ambient temperature is higher than
Use oil with greater viscosity.
that set for that moment.
The maximum permissible pressure, the temperature range and the
type of threaded coupling are indicated on the products.
General information
Mineral oils, for example HLP oils according to regulation DIN 51524
Recommended oils
part 2.
–– Summer oil: ISO VG 68
–– Winter oil: ISO VG 32
Recommended viscosity
For the material numbers see the “Pneumatics” catalogue of Bosch
Rexroth.
Assembly position Vertical
MR089 - 12
MECHANICAL ACTUATORS
MR
091Rev. 00
ASSEMBLY AND MAINTENANCE SHEET EN
TRANSLATION OF THE
ORIGINAL INSTRUCTIONS
SICA S.p.A. reserves the right to prosecute, within the terms of the law, whosoever reproduces this document or discloses the
contents to third parties without prior written authorisation.
The descriptions and illustrations contained in this manual are not binding, although the basic characteristics of the type of
machine described are not subject to variation.
The manufacturer reserves the right to make any modifications to the machine at any time in order to improve the end product,
with no commitment to updating the manual.
This manual must be kept for the entire lifetime of the machine in a location that is easily
accessible to all machine operators and maintenance personnel.
MR
091 Rev. 00
SUMMARY
ASSEMBLY.............................................................. 3
Version “R” Indirect (fig. 3)....................................... 5
Version "D" direct (fig. 2).......................................... 5
MAINTENANCE....................................................... 6
Check tightness........................................................ 6
Head fixing screws................................................... 6
Self-locking ring nut.................................................. 6
Transmission joint..................................................... 6
Shrink disc................................................................ 6
Actuators.................................................................. 7
Backlash control....................................................... 8
Bearing..................................................................... 8
Toothed belt.............................................................. 8
Ball screw / nut......................................................... 8
Lubrication................................................................ 8
Check wear.............................................................. 9
Anti-friction bushing.................................................. 9
Merkel guide strip..................................................... 9
Dismantling............................................................. 10
Isomove standard version (fig. 1)........................... 10
Version with direct motor drive (Fig. 2)................... 10
Version with indirect motor drive (Fig. 3).................11
Assembly.................................................................11
Ball screw / nut
(both versions, threaded and flanged).....................11
Toothed belt.............................................................11
Shrink discs and joints.............................................11
Shrink discs tightening torques.............................. 12
Joints tightening torques........................................ 12
This symbol indicates operations that can only be

carried out by expert technicians
MR091 - 1
MR maintenance sheet for:
091
Rev. 00
ANALYTICAL INDEX
A
Assembly (3)
M
Motor, Mounting (3)
Mounting the Motor (3)
R
Regular checks, Routine maintenance and (6)
Routine maintenance and regular checks (6)
–– Backlash control (8)
Ball screw / nut (8)
Bearing (8)
Toothed belt (8)
–– Check tightness (6)
Actuators (7)
Head fixing screws (6)
Self-locking ring nut (6)
Shrink disc (6)
Transmission joint (6)
–– Check wear (9)
Anti-friction bushing (9)
Merkel guide strip (9)
–– Lubrication (8)
U
Unscheduled maintenance (10)
–– Assembly (11)
Ball screw / nut (both versions, threaded and flanged) (11)
Joints tightening torques (12)
Shrink discs and joints (11)
Shrink discs tightening torques (12)
Toothed belt (11)
–– Dismantling (10)
Isomove standard version (fig. 1): (10)
Version with direct motor drive (Fig. 2) (10)
Version with indirect motor drive (Fig. 3) (11)
MR091 - 2
MR
091 Rev. 00
ASSEMBLY
MOUNTING THE MOTOR
ISOMOVE STANDARD MODULE Version

with flanged nut
Plug with mobile cleat

for greasing
Version
with threaded nut
Threaded plug
for greasing
Anti-rotation version Anti-rotation device made

made of plastic of bronze
Fig 1
N. Q.ty DESCRIPTION
1 1 FRONT HEAD
2 1 REAR HEAD
3 1 ISOMOVE JACKET
4 1 THREADED CONNECTION
5 1 STEM
6 1 LARGE SCREW
7 1 ROLLER
8 1 PISTON
9 1 ANTI-ROTATION ROD
9B - SCREWS
10 8 TCCE SCREWS
11 1 BEARING
12 1 SELF-LOCKING RING NUT
13 1 MERKEL GUIDE STRIP
14 1 MAGNETIC RING
15 2 GRUB SCREW UNI 5923
16 1 THREADED NUT
16 1 FLANGED NUT
17 1 SCREW 097F
18 1 TCEI PLUG SLIDING CLEAT
19 1 BUSHING
20 1 SCRAPER
MR091 - 3
091
Rev. 00
ISOMOVE Version "D"
N. Q.ty DESCRIPTION
00 1 ISOMOVE STANDARD
21 1 SHIM
22 1 MOTOR FLANGE Threaded plug
23 4 TSEI SCREW for locking joint
24 1 MOTOR
25 4 TCEI SCREW
26 1 SERVO JOINT
27 1 BEARING BLOCKING FLANGE Version with mobile
28 1 TCEI PLUG SLIDING CLEAT cleat plug for locking
28B 1 PRESSURE SCREW joint
29 1 CAP
Fig 2
ISOMOVE Version "R"

Fig 3
N. Q.ty DESCRIPTION
00 1 ISOMOVE STANDARD
21 1 MOTOR FLANGE
22 1 CASING
23 1 PULLEY SCREW
24 1 SHRINK DISC
25 1 TOOTHED BELT
26 4 TCEI SCREW
27 4 TCEI SCREW
28 2 TCEI SCREW
29 1 MOTOR
30 4 TCEI SCREW
31 4 SAFETY WASHER
32 6 SAFETY WASHER
33 1 SHRINK DISC
34 1 PULLEY
35 2 SIDE PANEL
36 8 TSEI SCREW
MR091 - 4
MR
091
Rev. 00
Version “R” Indirect (fig. 3)
• Unscrew the screws (28).

• Remove the casing (22).
• Position and screw in the motor (29) using the screws (30).
• Put the belt (25) on the pulleys (23) (34) with the shrink discs (24)
and (33) inserted.
• At the same time insert the pulley (23) on the motor shaft and the
pulley (34) on the end of the ball screw (06) (Fig. 1).
• Lock the shrink discs (24) and (35) according to the table “C” relative
to the shrink discs (for the type of shrink disc check the dimensions).
• Check that the pulleys are aligned and parallel.
• Put back the casing (22).
• Insert and lock the screws (28).
Version "D" direct (fig. 2)

• Position the joint (26) on the shaft of the motor (24) checking that
the axial position of the joint, once coupled to the motor and inserted
in the bell (22), is such that it allows the relative locking screw of
the joint itself to be reached using the hole on the spacer (21).
• Remove the motor (24) and tighten the joint (26) on the shaft of the
motor using the relative screw, respecting the tightening torques
shown in the table “D”. (For the type of joint, check the initials on
the joint itself).
• Position the motor (24) complete with joint (26) on the bell (22) and
lock it with the screws (25).
• Lock the joint (26) on the ball screw (06) (Fig. 1) ,referring to table
“D”, using the hole on the spacer (21).
• Plug the hole on the spacer (21) using the plug (28) that, depending
on the model, will be either threaded or with a mobile cleat.
MR091 - 5
091
Rev. 00
MAINTENANCE
ROUTINE MAINTENANCE AND REGULAR CHECKS
IT IS necessary to scrupulously follow the scheduled maintenance
operations summarised in the table below (Tab. “A”):
Table “A”
INTERVAL PART OPERATION Ref.
After 2 MONTHS from the installation
HEAD SCREWS CHECK TIGHTNESS Assembly - user manual
Within 6 months
LUBRICATION Use and maintenance manual
500 hours BALL SCREW
NUT BACKLASH SETEC ball screw catalogue
12-18 MONTHS JOINT CHECK TIGHTNESS Assembly - user manual
12 / 18 MONTHS SHRINK DISCS CHECK TIGHTNESS Assembly - user manual
12 / 18 MONTHS TOOTHED BELT CHECK BACKLASH Use and maintenance manual
12 / 18 MONTHS PULLEY CHECK ALIGNMENT Start-up checks - user manual
* In load conditions and when heavy work is being carried out, half the declared maintenance intervals.
Check tightness
Head fixing screws

check the tightness of the screws using a specific bush; in heavy
work conditions and with strong vibrations intensify the checks (for the
tightening torques see Table “B”);
Self-locking ring nut

the ring nut for locking the bearing has the job of axially restraining
the screw. The emergence of backlash, due to malfunctions, could
compromise the life of the bearing and the precision of the actuator's
positioning. To access the bearing, see the chapter "assembly and
disassembly".
Transmission joint
the joint has the task of transmitting the motion if there is a direct motor
drive “D” between the motor shaft and the ball screw. The joints used
are the zero backlash variety and use a clamp connection. To prevent
any slipping that could compromise the precision of the actuator's
positioning it is necessary to regularly check the tightness using torque
meter wrenches (the torques are shown in the table “D”). For the type
of joint, check the initials on the joint itself. For accessing the joint, see
the chapter "assembly and disassembly".
Shrink disc
the shrink disc has the task of locking the pulleys onto the relative
shaft, therefore make sure that is always locked well. The tightening
torques are shown in Table “C”. For the type of shrink disc, see its
dimensions. To access the shrink discs, see the chapter "assembly
and disassembly".
MR091 - 6
MR
091
Rev. 00
Actuators
The actuators are supplied with a thread locking system for the tightening
screws (soft Loctite); if customised actuators are purchased, some
screws are not locked in order to allow the motor to be assembled.
It is recommended that soft Loctite be applied once the assembly has
been carried out. More generally, the tables regarding the regulations
on tightening are attached below; the following norm establishes the
nominal torque values and the relative tolerances to be applied for
tightening the nuts and bolts according tot he applications. For the
selection of the tightening classes, see the Table B1 and establish the
bolt to be used, shown in Tab. B2, taking into consideration the tensile
forces of each single bolt (Tab. "B3").
Tolerances in reference
Applications Tightening class
Tab. “B1”
to the operating torque

I VERY HEAVY ±5%
II HEAVY 5% / -15%
III NOT SO HEAVY 5% / -35%
TIGHTENING CLASS
III II I
Width across of RESISTANCE CLASS OF THE SCREW
Threading the screw and/or
the nut 8.8 10.9 12.9
RESISTANCE CLASS OF THE NUT
8 10 12
M4 7 2.3 3.3 4
M5 8 4.8 6.8 8
M6 10 8 11.2 13.6
M8 13 20 28 32.8
M10 17 39.2 55.2 66.4
M12 19 68.8 96 116
M14 22 108 152 184 Tab. “B2”
Nm
M16 24 168 236 284 Tightening torque

M18 27 232 324 388
M20 30 328 464 552
M22 32 440 624 744
M24 36 568 800 960
M27 41 840 1200 1440
M30 46 1160 1600 1920
M4 7 3120 4360 5240
M5 8 5080 7160 8560
M6 10 7200 10080 12080
M8 13 13200 18560 22320
M10 17 20960 29520 35440
M12 19 30640 43200 51600
M14 22 42000 59200 70800 Tab. “B3”
N
M16 24 58400 81600 98400 Tensile force

M18 27 70400 99200 118400
M20 30 91200 128000 153600
M22 32 112800 159200 191200
M24 36 131200 184000 220800
M27 41 172000 241600 290400
M30 46 209600 294400 253600
MR091 - 7
091
Rev. 00
Backlash control
Bearing
The bearing used is the ”zero” backlash type with double angular
contact, however in heavy operating conditions it is wise to check the
axial backlash to ensure there are no positioning errors of the actuator
and that the component is not subjected rapid wear. If there is ever
any backlash, replace the bearing. For accessing the bearing, see the
chapter "assembly and disassembly".
Toothed belt
the tensioning of the belt cannot be regulated; if in certain conditions
there is an elongation of the belt, replace it. To access the belt, see
the chapter "assembly and disassembly".
Ball screw / nut

the nut is normally supplied with axial backlash, whose value can be
found in the SETEC catalogue (recirculating ball screws). Whenever, in
particular conditions, the axial backlash exceeds the nominal maximum
value, the screw/nut system should be replaced to prevent positioning
errors.
Lubrication
the actuator is supplied with the ball screw fully lubricated; since the
system is completely sealed, the lubrication phase can occur at quite
lengthy intervals (see Tab. “A” ), however regular lubrication helps limit
noise, reduce friction torque and therefore the heat generated. The
lubricants that can be used are the same as those used for lubricating
the bearings.
ISOMOVE LUBRICATION DIAGRAM Passage through hole for direct

lubrication of the screw
Hole on sleeve
Rod in extended position
Nut Ball screw
MR091 - 8
MR
091
Rev. 00
Lubrication is done manually and can be done by directly inserting

a nozzle into the sleeve of the actuator and dispensing the lubricant
directly onto the screw; to carry out this operation see the following
procedure (see Fig. 5 for the lubrication diagram):
• Take out the shaft (05) to the limit stop so that there is free access
to the screw (06).
• Unscrew the cap (18) of the screw of the mobile cleat if applicable.
• Insert the nozzle through the hole on the sleeve (03) of the actuator
until the screw is reached (06).
• Avoid overfilling with grease so as not to damage the actuator.
• The lubrication frequency can on average be equal to 500 hours
of operation; this recommendation is only indicative and could vary
depending on the type of application. For further information, see
the SETEC ball screw catalogue.
Check wear
Anti-friction bushing
the rod (05 - Fig.1) is connected radially since it is guided by a bushing
(19 - Fig. 1) made of low friction material. If ever there is any radial
backlash check the actuator is working correctly and if necessary replace
the bushing itself. To access the bushing, see the chapter "assembly
and disassembly".
Merkel guide strip

this is strip made of a polymeric material used on the piston as anti-
friction in contact with the sleeve. When the actuator is used in correct
installation conditions there should be no wear of the guide strip so
always check the assembly of the electro cylinder if any radial backlash
of the rod, and therefore of the piston, occurs.
MR091 - 9
091
Rev. 00
UNSCHEDULED MAINTENANCE
In all the cases where during regular maintenance the actuator has to
be dismantled, it would be wise to read the following recommendations
for the assembly and disassembly.
Dismantling
Isomove standard version (fig. 1):

• Unscrew with a suitable bushing the screws (10) of the heads
(01 - 02).
• Remove the head (01) from the rod (05).
• Extract the dust scrapers (20) and the bushing (19).
• Unscrew the ring nut (12) from the spigot of the screw (06).
• Take out the bearing (11) from the hole of the head (02) and from
the spigot of the screw (06).
• Remove the head (02) from the rear spigot of the screw (06).
• Remove the sleeve (03) from the rod/piston/screw unit.
• Take out the anti-rotation rod (09) from the sleeve (03) (where
applicable it is necessary to unscrew the screws (9B) to free the
anti-rotation).
• Unscrew the grub screws (15) from the piston (08).
• Unscrew the rod (05) from the piston (08).
• Unscrew the piston (08) from the nut (16) in the threaded nut
versions; Remove the fixing screws of the flange of the nut (16) in
the flanged nut versions.
• Remove the Merkel strip (13) and the magnetic ring (14) from the
piston (08).
• Bring the nut (16) towards the end of the screw (06).
Important
So that the balls do not come out during the extraction of the
nut, a tube must be placed in-between with an outer diameter
equal to the diameter corresponding to the rotation tracks of the
balls on the screws and with a length greater than that of the
nut. For more information, see the SETEC ball screw catalogue.
Version with direct motor drive (Fig. 2)
• Remove the threaded plug (28) or the screws (28B) of the sliding
cleat (28).
• move the rod (05) to rotate the joint (26) until the tightening screw
of the clamp is accessible passing through the hole on the spacer
(21) (in the versions with pressure plug (29) the process might not
require moving the rod).
• Unscrew the screws (25) and remove the motor (24).
• Remove the joint (26) from the motor shaft using the relative clamp
screw.
MR091 - 10
MR
091
Rev. 00
• Unscrew the screws (23) e and take out the motor flange (22) and
the spacer (21).
• Remove the joint (26) from the ball screw using the relative clamp
screw.
• Remove the flange locking the bearing (27).
Version with indirect motor drive (Fig. 3)

• Unscrew the screws (27 - 28) and remove the casing (22) to access
the indirect transmission assembly.
• Loosen the shrink discs (33 - 24) using the relative screws and
take out the belt (25) and the pulleys (23 - 34).
• Unscrew the screws (30).
• Take out the motor (29)
• Unscrew the screws (26) and take out the standard ISOMOVE
body (00).
Assembly
Generally, it is possible to carry out the assembly reversing the
disassembly procedure of the relative versions, paying particular attention
to the assembly of the following parts:
Ball screw / nut (both versions, threaded and flanged)

If the nut needs replacing we will supply you with the component on
which there is a small tube; never extract the tube, otherwise the balls
will come out.
The tube should be removed from the nut progressively as the nut is
screwed onto the threading of the ball screw. The tube should rest against
the start of the threading of the ball screw in a seamless manner; the
balls roll on a diameter approximately equal to the outer diameter of
the tube; in this way the balls can be held within the housing of the nut
until the start of the screw's threading is found. For further information,
see the SETEC "ball screws" catalogue.
Toothed belt
To prevent excessive stress on the bearings of the shafts on which the
pulleys are coupled and to prevent misalignments in the event of the
belt being replaced, it is good to loosen the screws of the shrink discs
(24 - 33) in order to reduce the tensioning to be applied to the belt. By
tightening the shrink discs you automatically obtain adequate tensioning
and centring. Ultimately you always need to check the alignment of the
belt, making sure that it does not croooossed.
Shrink discs and joints

In order to ensure the adequate transmission of motion from the motor
shaft to the screw it is indispensable that the screws of the joints and of
the shrink discs are tightened with the correct tightening torque. (See
Tab. “C” for the tightening torques of the shrink discs and Tab. “D” for
the tightening torques of the joints.
For the type of joint and shrink disc see the marking on them.
MR091 - 11
091
Rev. 00
Tab. “C”
Tightening torque
DIN 912 Tightening
mm
12.9 torque
dXD No. x type Nm
6 x 16 3 x M2.5 1.2
6.35 x 16 3 x M2.5 1.2
7 x 17 3 x M2.5 1.2
8 x 18 3 x M2.5 1.2 Shrink discs tightening
9 x 20 4 x M2.5 1.2 torques
9.53 x 20 4 x M2.5 1.2
10 x 20 4 x M2.5 1.2 Measure the inner diameter of
11 x 22 4 x M2.5 1.2 the pulley mounting and the
12 x 22 4 x M2.5 1.2
diameter of the shaft; based
14 x 26 4 x M3 2.1
on the data obtained, identify
the corresponding shrink disc
15 x 28 4 x M3 2.1
and make note of the correct
16 x 32 4 x M4 4.9
tightening torque in the column
17 x 35 4 x M4 4.9
called “Tightening torque”.
18 x 35 4 x M4 4.9
19 x 35 4 x M4 4.9
20 x 38 4 x M5 10
22 x 40 4 x M5 10
24 x 47 4 x M6 17
25 x 47 4 x M6 17
25.4 x 47 4 x M6 17
28 x 50 6 x M6 17
30 x 55 6 x M6 17
32 x 55 6 x M6 17
35 x 60 8 x M6 17
38 x 65 8 x M6 17
40 x 65 8 x M6 17
42 x 75 6 x M8 41
45 x 75 6 x M8 41
48 x 80 8 x M8 41
50 x 80 8 x M8 41
Tab. “D”
Tightening
D1 D2 DIN
Type torque
mm mm 912
Nm
ADS 10 6 16 M4 5
ADS 18 10 24 M5 10
ADS 60 14 32 M6 18
ADS 150 16 38 M8 43 Joints tightening torques
ADS 300 24 45 M 10 84
Measure the diameter of the
DKN 20/42 3 12.7 M3 1
motor shaft and the spigot
of the screw; based on the
data obtained, identify the
corresponding joint and make
note of the correct tightening
torque in the Table "D".
MR091 - 12
TOUCH SCREEN Terminal
(UNIBELL 200-400-500 BELLING MACHINE)
READ THIS MANUAL

BEFORE USE
OPERATING GUIDE EN
UM - 100400-09
UM - 100400
Instructions translated 08 - 2015 Rev. 10
from the original
C023510710.fm
Machine No.
language 1507903
SICA S.p.A. reserves the right to use any legal means available against whoever reproduces, copies or divulges this document or its
content to third parties, without written consent.
Descriptions and illustrations featured in this manual are not to be regarded as binding with the exception of the specification of the type
of machine described. The manufacturer reserves the right to make any changes required to improve the product at any time without
updating the content of this manual.
(UNIBELL 200-400-500 BELLING MACHINE)
SICA S.p.A.
UM - 100400-09

C.F./P.Iva IT00084440395
Tel. ++39/0544/88711 - Fax ++39/0544/81340
C023510710.fm
Customer Service
Tel. ++39/0544/88774 - Fax ++39/0544/88821
SUMMARY
1 GENERAL INFORMATION......................... 3 4.5. Recipe manager menu.............................. 39
Program selection .......................................39
1.1. Purpose of the manual................................. 3
Editing programs.........................................40
1.2. Manufacturer nameplate.............................. 4 Loading programs .......................................41
1.3. Technical service request procedures ......... 4 Deleting programs.......................................41
Transfer of programs on removable
1.4. Terms and Definitions.................................. 4 device..........................................................42
1.5. Safety regulations ........................................ 5 4.6. Machine parameters menu ........................ 43
2 TECHNICAL INFORMATION...................... 6 4.7. DISPLAY alarms menu ............................. 46
Acknowledgement of an alarm....................47
2.1. General description of the operating
terminal ........................................................ 6 4.8. Alarm conditions ........................................ 48
4.9. Replacing the PLC DISPLAY batteries ...... 51
3 SAFETY INFORMATION ............................ 7
3.1. General Safety Regulations......................... 7
4 ABOUT USE................................................ 8
4.1. Turning the operator’s terminal on and off... 8
Turning on.....................................................8
Turning off.....................................................8
4.2. How to use the operator’s terminal .............. 8
Modifying or entering values.......................10
4.3. Process display and editing menu ............. 11
Page 1 ........................................................11
Page 2 ........................................................12
Page 3 ........................................................12
Page 4 ........................................................13
Page 5 ........................................................14
Page 6 ........................................................14
Page 7 ........................................................15
Page 8 (for IR-SW oven) ............................16
Page 9 ........................................................17
Page 10 ......................................................18
Page 11 ......................................................18
Page 12 ......................................................19
Page 13 (for IR-SW oven) ..........................19
Page 14 (for IR-SW oven) ..........................20
Page 15 ......................................................20
Page 16 ......................................................21
Page 17 ......................................................21
Page 18 ......................................................22
Page 19 ......................................................23
Page 20 ......................................................24
Page 21 ......................................................25
Page 22 ......................................................26
Page 23 ......................................................26
Page 24 ......................................................27
UM - 100400-09
4.4. Enabling manual controls menu ............... 28

IN23510710.fm
-1-
ANALYTICAL INDEX
A T
Alarm conditions (48) Technical service request procedures (4)
Alarm state (48) Terms and Definitions (4)
Assistance request, modes (4) Turning the operator’s terminal on and off (8)
D
DISPLAY alarms menu (46)
- Acknowledgement of an alarm (47)
E
Enabling manual controls menu (28)
G
General description of the operating terminal (6)
General safety regulations (7)
H
How to use the operator’s terminal (8)
- Edit or enter values (10)
M
Machine parameters menu (43)
Manual, aim of (3)
Manufacturer nameplate (4)
P
Process display and editing menu (11)
- Page 1 (11)
- Page 2 (12)
- Page 3 (12)
- Page 4 (13)
- Page 5 (14)
- Page 6 (14)
- Page 7 (15)
- Page 8 (for IR-SW oven) (16)
- Page 9 (17)
- Page 10 (18)
- Page 11 (18)
- Page 12 (19)
- Page 13 (19)
- Page 14 (for IR-SW oven) (20)
- Page 15 (20)
- Page 16 (21)
- Page 17 (21)
- Page 18 (22)
- Page 19 (23)
- Page 20 (24)
- Page 21 (25)
- Page 22 (26)
- Page 23 (26)
- Page 24 (27)
R
Recipe manager menu (39)
- Deleting programs (41)
- Editing programs (40)
- Loading programs (41)
- Program selection (39)
- Transferring programs onto a removable device (42)
UM - 100400-09
Replacing the PLC DISPLAY batteries (51)

S
Safety regulations (5)
Safety, instructions (5)
IN23510710.fm
Support, requesting methods (4)
-2-
Chapter 1
GENERAL INFORMATION
1.1. PURPOSE OF THE MANUAL

– The manual herein, part and parcel with the equipment, has been pre-
pared by the manufacturer of the machine it is installed on with the pur-
pose to supply the necessary information to the persons authorized to
operate it during its useful life.
– As well as adopting an appropriate utilization technique, the recipients
of the information must read and strictly apply them.
– This information is supplied by the manufacturer in its own language
(Italian) and may be translated into other languages to satisfy statutory
and/or sales needs.
A little time dedicated to the study of this information, will permit the user
to avoid health and safety risks to personnel and economic loss.
NAL INSTRUCTIONS".
– In case in which, in this manual, there is additional information regard-
ing the actual setup of the equipment, it does not interfere with the read-
ing.
– Keep this manual for the entire duration of the equipment useful life in
a well known and easy to access place, available for reference any time
the need should arise.
– In order to highlight some parts of the text which are especially impor-
tant or to indicate some important specification, a few symbols, whose
meaning is described hereunder, have been adopted.
Danger - Warning
Indicates situations involving great hazard risks which, if over-
looked, could put people’s health and safety in great danger.
Caution - Beware
Important
not be overlooked.
UM - 100400-09
C123510710.fm
-3-
Chapter 1
GENERAL INFORMATION
1.2. MANUFACTURER NAMEPLATE

When the machine is switched on,
the start screen is displayed, show-
ing the manufacturer’s identity da-
ta. C
Key
A – Manufacturer nameplate A
B – Type of machine on which the
equipment is installed B
C – Current date and time.
40014404900.tif
1.3. TECHNICAL SERVICE REQUEST

PROCEDURES
For any requirement, please contact the Manufacturer’s Customer Ser-
vice.
For any request for technical service, provide the equipment model, the
approximate number of hours the machinery has been used and the type
of malfunction.
In order to facilitate the exchange of information in case of telephone as-
sistance request, the icon of each control or parameter is provided with a
univocal identification number.
1.4. TERMS AND DEFINITIONS

The glossary provides explanations for a number of the terms used fre-
quently in the manual.
– Field: part of the monitor of the operating terminal, linked to a function
and/or part of the machine, that can group together icons and/or zones
of visualisation or value setting.
– Icon: symbol or image that represents a command or a function in a
stylised fashion.
– General trained operator: A technician appointed and authorised by
the Line manager, with the requisites, skills and knowledge necessary to
use the operating terminal (i.e. setting operating parameters, etc.) in
complete safety. The operator must report all machine malfunctions not-
ed to the line manager. The operator must not carry out any operation
that, according to the manual, is to be performed by a qualified techni-
cian. He should not carry out any operations that require access to the
UM - 100400-09
inside of the machine.

– Line manager: A technician with proven experience in managing extru-
sion lines where the operating terminal is installed. He is responsible for
C123510710.fm
selecting and training personnel employed in the operation of the produc-

tion line in which the machine is installed. The line manager holds and is
responsible for the keys for restricted machine controls.
-4-
Chapter 1
GENERAL INFORMATION
The line manager is also responsible for authorising and supervising all
work necessary on the machine and ensuring that it is conducted in safe-
ty.
– Expert technician: A technician, authorised by the line manage, with
proven experience in the use and maintenance of the operating terminal
on extrusion lines. He will have proof that he has taken training courses
held by the manufacturer specifically for running and managing these
machines. He should have all the information needed for the installation,
the format change operations, and the use and maintenance of the oper-
ating terminal. He should not perform any operation without prior author-
isation from the line manager.
– Zone: part of the monitor of the operating terminal, suitably defined,
through which the values of a single parameter can be viewed and set.
1.5. SAFETY REGULATIONS

– The company declines all liability for damages for an improper use of
the equipment, failure to respect or apply the indications given in this user
manual and modifications and/or tampering.
– The operator, as well as being adequately trained and informed on the
use of the machinery, must possess skills and competence adequate to
the type of working activity to perform.
– Only use the equipment for the purposes intended by the manufacturer.
Improper use may cause risks to the safety and the health of personnel
or economic loss.
– Prevent access to the equipment by unauthorised persons, particularly
during maintenance and adjustment phases.
– All repair operations must be carried out only by qualified personnel,
with recognised experience acquired in the specific sector of interven-
tion.
– The Waste of Electrical and Electronic Equipment may contain hazard-
– When decommissioning the machine separate all the components ac-
UM - 100400-09

C123510710.fm
-5-
Chapter 2
2.1. GENERAL DESCRIPTION OF THE

OPERATING TERMINAL
The operating terminal is designed and built to manage the operating
functions for the machine on which it is installed. It is installed on the ma-
chine for use by the operator.
Important
Due to the complexity of the functions it has to carry out, this equip-
ment must be used by suitably trained personnel, whose actual
competence has been checked.
The main parts are listed below.
A – Digital display
The machine’s processes can be displayed and managed in area (A1).
Area (A2) is reserved for displaying "alarm messages".
The icons in area (A3) are used to access the various menus.
In order to consult the various menus simply "touch" the relevant icon
with your finger (touch screen technology).
The pages that follow describe the various functions and ways in which
the menus can be consulted.
A1
A3 A
40014400100.tif
A2
UM - 100400-09
C223510710.fm
-6-
Chapter 3
SAFETY INFORMATION
3.1. GENERAL SAFETY REGULATIONS

– The company declines all liability for damages for an improper use of
the equipment, failure to respect or apply the indications given in this
user manual and modifications and/or tampering.
– The operator, as well as being adequately trained and informed on the
use of the machinery, must possess skills and competence adequate to
the type of working activity to perform.
– Only use the equipment for the purposes intended by the manufacturer.
Improper use may cause risks to the safety and the health of personnel
or economic loss.
– Prevent access to the equipment by unauthorised persons, particularly
during maintenance and adjustment phases.
– All repair operations must be carried out only by qualified personnel,
with recognised experience acquired in the specific sector of interven-
tion.
– The Waste of Electrical and Electronic Equipment may contain hazard-
– When decommissioning the machine separate all the components ac-
UM - 100400-09
C323510710.fm
-7-
Chapter 4
ABOUT USE
4.1. TURNING THE OPERATOR’S TERMINAL ON

AND OFF
Turning on
In order to switch the operator’s terminal on, turn the main switch on the
machine to the "I" position. The operator’s terminal switches on and the
display shows the start screen.
Turning off
In order to switch the operator’s terminal on, turn the main switch on the
machine to the "O" position. The operator’s terminal switches off auto-
matically.
4.2. HOW TO USE THE OPERATOR’S TERMINAL

In order to facilitate consultation of the pages in the main menu and re-
lated sub-menus, refer to the diagram below.
Activation of control
panel
MANUAL MANUAL
CONTROLS 1 CONTROLS N
RECIPES 1 RECIPES N
LIST OF
RECIPES
SETUP OF PROTECTED PROTECTED

PROCESS 1 THE STATISTICS PAGES 1 PAGES N
PANEL
UM - 100400-09
ACTIVE ALARM
PROCESS N ALARMS RECORDS
C423510710.fm
40020600100.tif
-8-
Chapter 4
ABOUT USE
Each page includes the icons used to access the main menus.
F F A
40025109400.tif
Key
A – Icon for accessing the "Display and edit processes" menu.
B – Icon for accessing the "Activate manual commands" menu.
C – Icon to access "Recipe management" menu
D – Icon for accessing the "Machine parameters" menu.
E – Icon for accessing the "Display alarms" menu.
F – Icon for scrolling pages that cover a number of pages.
In order to facilitate the exchange of information in case of tele-
phone assistance request, the icon of each control or parameter is
provided with a univocal identification number.
Important
To display the icon identification number you must activate the corre-
sponding function in the "Machine Parameters" menu. You are ad-
vised to keep the function active, as the same identification numbers
seen on the screen are also used in the manual, to refer to the icons
mentioned.
The figure shows an example.

– Icon (H)
– Identification number of icon (L)
The numbers (0÷99) identify gener- H
al icons.
The numbers (100÷299) identify
icons of the "Process" menu.
UM - 100400-09
The numbers (500÷699) identify L

40020608000.tif
icons of the "Programs" menu.

C423510710.fm
The icons of the "Programs" and

"Process" menus that identify
the same functions have similar
-9-
Chapter 4
ABOUT USE
identification numbers (e.g. icon 121 of the "Programs" menu cor-

responds to icon 21 of the "Process" menu).
The numbers (200÷299) identify icons of the "Manual controls" menu.
The numbers (300÷399) identify general icons of the "Programs" menu.
The numbers (500÷599) identify icons of read-only parameters (immedi-
ate values).
Modifying or entering values

Proceed as indicated
40025107400.pdf
1 – Touch the parameter you wish
to set on the display. A "keyboard"
or "numpad" is displayed.
2 – Enter the value on the keyboard
and touch button "Enter" to confirm.
3 – Touch the "CLR" (Clear) key to
cancel the value entered, touch
"BS" (Backspace) to delete the last
digit entered, or touch "CANCEL"
or "ESC" to annul the operation.
40025100100.pdf
UM - 100400-09
C423510710.fm
- 10 -
Chapter 4
ABOUT USE
4.3. PROCESS DISPLAY AND EDITING MENU

This function can be used to set or edit production parameters.
When the machine has been started up on automatic mode, set param-
eters can be consulted or edited, and operations can be done to the work
cycle.
This menu includes a number of pages. To scroll back or forward see the
4.2. - "How to use the operator’s terminal" section.
For some parameters, the current value (white background) is shown
along with the value set (grey background).
Important
Parameters which call up the keyboard (numerical or alphanumeri-
cal) when touched are modifiable, all others are read-only.
The list shows all the parameters to be found on the various pages of the
menu. The order they are in and/or inclusion may differ depending on the
model of the machine on which the operating terminal is installed.
Page 1
– “Current Program” field: to dis-

play the program identification da- 1
ta.
40027700100.tif
Zone (15): shows the name of the
program in use.
If the memory is full, the new pro-

gram cannot be stored. The screen
shown will appear on the monitor.
Important
Activating the "new program"
icon, the program will be stored
with the same name as the cur-
rent program. To make it easier
to recognise, modify the name 40017903600.tif
of one of the programs as soon

as possible (see 4.5. - "Recipe
manager menu").
– “Save program” icon:
Icon (16): touch the icon to save
the changes made to the selected
23510711500.gif
program.
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- 11 -
Chapter 4
ABOUT USE
Icons (10-11) appear on the dis-

play.
Icon (10): touch icon to confirm the
modifications.
Icon (111): touch icon to exit with-
23510711600.gif
out saving.
Page 2
– “Rapid access menu” icon:

used to directly access the menus
of the various devices.
Icon (80): Touch the icon to directly
access the menu of the pipe haul-
off device.
access the menu of oven 2.
access the menu of oven 2.
access the menu of the belling cy-
cle.
235107046-00
Page 3
– “Working cycle” icon: to select

the operating cycle of the machine.
Icon (107): Touch the icon to ena-
ble or disable the belling cycle.
ON: belling cycle activated.
OFF: belling cycle deactivated.
Icon (105): Touch the icon to acti-
vate or deactivate the pipe entry.
ON: Pipe entry activated.
OFF: pipe entry deactivated.
235107117-00
UM - 100400-09
C423510710.fm
- 12 -
Chapter 4
ABOUT USE
Page 4
– “Forming cycle” icon: to select

the desired forming cycle.
Icon (11): Touch the icon to select
the desired belling cycle.
0 - “Smooth Mandrel” cycle: bell-
0
ing process for the smooth socket,
obtained by using a smooth metal
mandrel. The correct socket form-
1
ing carried out through the external
air pressure on the socket and si-
multaneous cooling .
2
1 - Segments “In cycle”: socket
belling process with gasket seat,
23510704700.gif
obtained with a metal mandrel with 3
expandable segments. The seg-
ments protrude from the mandrel
when the latter penetrates inside
the pipe. The correct socket form-
ing carried out through the external air pressure on the socket and simul-
taneous cooling .
2 - “Segments Out” cycle: socket belling process with gasket seat, ob-
tained with a metal mandrel with expandable segments. The segments
protrude from the mandrel before the latter penetrates inside the pipe.
The correct socket forming carried out through the external air pressure
on the socket and simultaneous cooling .
3 - “RIEBER” cycle: Socket belling process with seat complete with gas-
ket, made with smooth metal mandrel that loads and places the gasket.
The correct forming of the seat is carried out through the action of the
vacuum inside the socket, the external air pressure on the socket and the
cooling.
UM - 100400-09
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Chapter 4
ABOUT USE
Page 5
– “Production batch” field: used

to set the count of pipes for belling.
Icon (108): touch the icon to acti-
vate (ON) or deactivate (OFF) the
belled pipes count. When the func-
tion is activated, the field value
(500) resets.
Zone (109): touch the zone to set
23510711800.gif
the parameter.
Zone (500): displays the number of
belled pipes.
– “Cutting pulses” field: used to

manage the signal arriving from the
machine installed upstream from
the belling machine and indicating
that the pipe has been cut.
cut pipes count.
Icons (111-112): touch the icons to
increase or decrease the value
23510711900.gif
shown in zone (501).
Zone (501): shows the number of
cut pipes still to be belled.
Page 6
– “Pipe feed” field: used to set the

speed (in meters/minute) of the
tube arrival conveyor.
– Zone (120): touch the zone to set
the parameter.
23510704800.gif
– “Haul-off down delay” field: set

the activation delay time (in sec-
onds) for the haul-off device to de-
scend and haul off the pipe, once
the latter has been detected by the
23510704900.gif
photocell on the arrival conveyor.

UM - 100400-09

the parameter.
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- 14 -
Chapter 4
ABOUT USE
– “Bench movement” field: used

to raise and lower the bench.
Zone (330): touch the icon to
raise the bench. When released
the movement stops.
23510713000.gif
Zone (331): touch the icon to lower
the bench. When released the
movement stops.
Page 7
– “Pipe heating adjustment”

icon: used to adjust the settings for
heating the pipe.
– Oven 1 - external heating field:
used to set the operation parame-
ters of the external lamps of oven 1.
external heating of oven 1.
the preheating time for oven 1 (in
seconds).
Zone (607): displays the instanta-
235107051-00
neous value of the preheating time
(in seconds).
the heating time for the oven (in
seconds).
Zone (503): displays the instantaneous value of the heating time of oven
1 (in seconds).
Zone (151): touch zone to set the position of the pipe pre-heating (in mil-
limetres).
Zone (542): displays the position of the pipe pre-heating (in millimetres).
Zone (152): touch zone to set the position of the pipe heating (in millime-
tres).
Zone (539): displays the position of the pipe heating (in millimetres).
Zone (145): touch the zone to set the working temperature of the external
lamps of oven 1.
Zone (504): shows the effective temperature of the outer surface of the
pipe.
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Chapter 4
ABOUT USE
Page 8 (for IR-SW oven)
“Pipe rolling time” field: used to

set the time (in seconds) of the ro-
tation of the pipe for each direction
(alternately clockwise and anti-
clockwise) during the heating.
Zone (143): Touch area to set the
pipe rotation time clockwise.
pipe rotation in an anti-clockwise.
Important
The set time must allow the pipe
to carry out at least one full rota-
235107135-00
tion.
– “Oven 1 - Internal heating” field:
ters of the internal lamps of oven 1.
Zone (147): touch the zone to set the activation percentage of the exter-
nal lamps 1 of oven 1.
Zone (148): touch the zone to set the activation percentage of the exter-
nal lamps 2 of oven 1.
Zone (155): touch the icon in correspondence with the option to activate.
0 - Oven without lamps.
1 - Oven with small lamps.
2 - Oven with medium lamps.
3 - Oven with large lamps.
Zone (152): touch the zone to set the activation percentage of the external
lamps of oven 1.
Zone (154) : touch the zone to set the position of the oven
lamps of oven 1.
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- 16 -
Chapter 4
ABOUT USE
Page 9

heating the pipe.
– “Oven 1 - external heating”
field: used to set the operation pa-
rameters of the external lamps of
oven 1.
seconds).
235107136-00
(in seconds).
the heating time for the oven (in seconds).
1 (in seconds).
limetres).
Zone (152): touch zone to set the position of the pipe heating (in millime-
tres).
Zone (539): displays the position of the pipe heating (in millimetres).
lamps of oven 1.
pipe.
“Oven fan” field: used to activate and deactivate the fan.

Icon (248): touch the icon to activate (ON) or deactivate (OFF) the cool-
ing fan of oven 1.
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Chapter 4
ABOUT USE
Page 10
“Pipe rolling time” field: used to

set the time (in seconds) of the ro-
tation of the pipe for each direction
(alternately clockwise and anti-
clockwise) during the heating.
pipe rotation time clockwise.
pipe rotation in an anti-clockwise.
Zone (154) : Touch the zone to set
235107137-00
the position of the oven.
Page 11
– “Enabling marking device”

field: used to activate and deacti-
vate the marker device.
vate the automatic marking cycle.
“Marking start cycle” icon: used
to start the marking cycle manually.
Icon (171): Touch the icon to force
the pipe circumference marking.
“Centring device delay” field:

used to set the delay time (in sec-
onds) for activating the centring de-
235107150-00
vice, after the marking device has
started to move forward.
the parameter.
“Marking device position”: used to set the position of the marker (in
millimetres).
Zone (175) (if present): touch the zone to set the position of the marker
(in millimetres).
Zona (531) (if present): displays the instantaneous value (in millimetres)
of the position of the marker.
“Marker pen delay” field: used to set the activation delay time (in sec-
onds) of the marker pen activation, after lowering of the pipe pressing
unit.
Zone (173): touch the zone to set the parameter.
UM - 100400-09
“Marking time” field: used to set the time (in seconds) the marker pen
stays on the pipe.
C423510710.fm
- 18 -
Chapter 4
ABOUT USE
Page 12
– “Enabling chamfering unit”

vate the operation of the chamfer-
ing machine.
vate the automatic chamfer cycle.
“Chamfer time” field: used to set

the time (in seconds) of the pipe
chamfer.
the parameter.
235107138-00

heating the pipe.
oven 2.
Zone (191): touch zone to set the
position of the pipe pre-heating (in
millimetres). 235107054-00
Zone (541): displays the position of

the set pipe heating (in millimetres).
neous value of the pipe preheating
time (in seconds).
Zone (182): touch the zone to set the heating time for the oven (in sec-
onds).
Zone (503): displays the instantaneous value of the pre-heating time of
oven 2 (in seconds).
Zone (181): touch the zone to set the preheating time for oven 1 (in sec-
onds).
Zone (540): displays the instantaneous value of the preheating time (in
UM - 100400-09
seconds).
lamps of oven 1.
C423510710.fm
pipe.
- 19 -
Chapter 4
ABOUT USE
– “Oven 2 - Internal heating” field:

ters of the internal lamps of oven 2.
the activation percentage of the ex-
ternal lamps 2 of oven 2.
the activation percentage of the ex-
ternal lamps 2 of oven 2.
Zone (195): touch the icon in corre-
spondence with the option to acti-
vate.
0 - Oven without lamps.
235107139-00
1 - Oven with small lamps.
2 - Oven with medium lamps.
3 - Oven with large lamps.
Zone (192): touch the zone to set the
activation percentage of the external
lamps of oven 2.
Zone (194) : touch the zone to set the position of the oven.
Page 15

heating the pipe.
oven 2.
seconds).
235107136-00

(in seconds).
the heating time for the oven 2 (in seconds).
2 (in seconds).
UM - 100400-09
limetres).
Zone (541): displays the position of the set pipe heating (in millimetres).
C423510710.fm
- 20 -
Chapter 4
ABOUT USE
lamps of oven 1.
pipe.
“Oven fan” field: used to activate and deactivate the fan.
Icon (248): touch the icon to activate (ON) or deactivate (OFF) the cool-
ing fan of oven 2.
Page 16
“Pipe heating adjustment” icon:

used to adjust the settings for heat-
ing the pipe.
Zone (194) : touch the zone to set
the position of the oven
235107146-00
Page 17
– “Dryer” field: used to activate

and deactivate the dryer operation.
23510705600.tif
device operation.
Important
The command is enabled in both manual operation mode (MAN) and
automatic operation mode (AUT).
– “Socket cooling” field: used to

activate and deactivate the devices
23510705700.tif
of the socket cooling system (wa-

ter-operated).
Icon (213): Touch the icon that cor-
responds to the option to be acti-
vated.
AUTO: cooling circuit activated.
OFF: cooling circuit deactivated.
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Chapter 4
ABOUT USE
– “Socket cooling” field: used to

activate and deactivate the cooling
23510714000.tif
fan (air) of the socket.
Icon (215): Touch the icon that cor-
responds to the option to be acti-
vated.
AUTO: fan managed in automatic
mode.
ON: the fan always stays on.
Page 18
– “Belling cycle mode” field: used

to select the socket forming cycle
operating mode.
Field (210): touch the field and se-
23510709000.tif
lect the desired belling mode.
EP only the external pressure is en-
abled in the forming chamber
(E.P.).
EP + VACUUM both the external
pressure in the forming chamber
(E.P.) and the negative internal
pressure in the mandrel (Vacuum) are enabled.
– “EP amber anti-collision posi-

tion control” field: allows the po-
sitioning values that have been set
to be displayed.
Zone (211): displays the anti-colli-
23510709100.tif
sion value set between the EP
chamber and the carriage.
Zone (212): displays the anti-colli-
sion value set between the EP
chamber and the flange.
– “Telescopic chamber anti-colli-

sion position control” field: al-
lows the positioning value that has
been set to be displayed.
Zone (212): displays the value set
23510709151.tif
regarding the anti-collision be-

tween the loading flange and the
carriage.
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Chapter 4
ABOUT USE
Page 19
– “Flange withdrawal delay” field:

used to set the flange withdrawal
23510709200.tif
delay time (in seconds) after com-
plete forming carriage workfeed
(RIEBER cycle only).
the parameter.
Zone (519): shows the immediate
value of the parameter.
– “E.P. delay” field: used to set the

socket external pressure activation
23510709400.tif
delay time (in seconds) after com-
plete forming carriage workfeed.
the parameter.
– “Mandrel pre-cooling delay”

field: used to set the mandrel air
23510709700.tif
pre-cooling phase delay time (in
seconds) after the complete ad-
vancement of the forming carriage
(RIEBER cycle excluded).
The mandrel pre-cooling phase
ends when "pipe cooling time"
(224) starts.
Zone (520): shows the immediate value of the parameter.
– “E.P. time” field: used to set the

duration time (in seconds) of the
23510709300.tif
external pressure on the socket.

the parameter.
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- 23 -
Chapter 4
ABOUT USE
– “External cooling time” field:

used to set the socket external
pressure and cooling duration time
23510709500.tif
(in seconds), after "E.P. time" (223)
has elapsed.
the parameter.
– “Pipe dripping time” field: used

to set the external pressure dura-
23510709800.tif
tion time (in seconds) to remove
excess water inside the pipe, after
the "external cooling time" (224)
has elapsed.
the parameter.
Page 20
– “Mandrel cooling time” field:

used to set the duration (in sec-
23510709900.tif
onds) of the mandrel cooling phase
activation, after the complete with-
drawal of the forming carriage
(RIEBER cycle excluded). The
cooling phase of the mandrel ends
when the set time expires or when
a new tube arrives in the forming
station.
the parameter.
– “Ring gripper stop delay” field:

used to set the delay time (in sec-
23510710000.tif
onds) for stopping the ring gripper

once the ring itself has been inter-
cepted.
the parameter.
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- 24 -
Chapter 4
ABOUT USE
– “Vacuum time” field: used to set

the vacuum activation time (in sec-
23510710100.tif
onds) inside the socket (RIEBER
cycle only). The "vacuum time" be-
gins at the same time as the "E.P.
delay" (221) and terminates at the
end of the set time or when "pipe
dripping time" (225) has elapsed.
– “Lubrication time” field: used to

set tool lubrication time (in sec-
23510710200.tif
onds) for ring lubrication.
the parameter.
– “Time-out for total belling time”

field: used to set the maximum
23510710300.tif
time (in seconds) within which the
belling cycle must be completed.
the parameter.
Page 21
– “Carriage position” field: used

to set the positions (in millimetres)
of the forward or backward moving
position of the forming carriage.
23510715200.tif

the backward moving position of
the carriage.
the forward position of the carriage.
Zone (252) (if present): touch the
zone to set the ring loading position
of the carriage.
Zone (538): shows the immediate value of the carriage workfeed position
compared to the pipe.
Zone (540): shows the immediate value of the carriage position where
UM - 100400-09
the tube is intercepted.

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- 25 -
Chapter 4
ABOUT USE
Page 22
– “Flange position” field: used to

set the flange positioning points (in
millimetres).
the backward moving position of
the flange at the end of the socket
23510710900-23510710800.tif
belling cycle.
the ring positioning or pipe upset-
ting position in conformity with the
belling cycle.
– “Flange heating” field: used to

activate and deactivate the heating
of the flange, and set its tempera-
ture.
23510711000.tif
heating of the flange.
the heating temperature of the
flange.
Zone (247): touch the zone to set the current absorption value of the
flange heating elements below which the system generates the
"FLANGE CURRENT" alarm.
Page 23
– “E.P. chamber positions” field:

used to set the positioning posi-
tions (in millimetres) of the E.P.
chamber.
the withdrawal position of the E.P.
23510711300.tif
chamber carriage.
– Zone (529): shows the immediate
UM - 100400-09
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- 26 -
Chapter 4
ABOUT USE
Page 24
– “Link position” field: used to set

the unloading positions of the link.
the unloading position 1 of the long
pipes.
23510711310.tif
the unloading position 1 of the long
pipes.
the unloading position of the short
pipes.
Zone (250) (only for co 1428601):
touch the zone to set the forward
speed (in m/min) of the links.
Zone (529): shows the instantaneous value of the link position.
UM - 100400-09
C423510710.fm
- 27 -
Chapter 4
ABOUT USE
4.4. ENABLING MANUAL CONTROLS MENU

Manual controls are used to enable machine components one by one in
case of maintenance or operation test.
Controls are only enabled if the mode selector switch is set to MAN (man-
ual).
1 – Turn the mode selector switch (7) to "MAN".
2 – Press button "Manual commands" in order to show the first page of
"MANUAL COMMANDS" function on the display.
3 – Identify the movement of the required machine component on this
page.
4 – Use the commands on the operating terminal to activate the hydraulic
power unit and wait until oil pressure and temperature reach suitable val-
ues.
5 – Press the function key shown to start the electric motor or correspond-
ing actuator.
Important
In certain cases, the key must be kept pressed to start the device; re-
leasing it causes the device to stop immediately. In other cases, press-
ing the key causes the device to start.
40027708500.pdf
21
4 7
UM - 100400-09
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- 28 -
Chapter 4
ABOUT USE
6 – To activate one of the move-

ments driven by hydraulic power
when the interlocked mobile
guards are open, simultaneously
press button (21) and the com-
mand on the operating terminal (4).
If the procedure is performed incor-
rectly, the warning window depict-
ed is displayed.
Touch the area (X) to close the
40025109300.pdf
warning window.
Important
The operation described is carried out only if strictly necessary and
only after having ensured that there are no personnel inside the ma-
chine.
7 – To leave the manual operation mode, rotate the mode selector (7) to
position "0".
After these operations, the machine is switched on in "STOP CYCLE" mode.
40027708500.pdf
21
4 7
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- 29 -
Chapter 4
ABOUT USE
The list shows all the commands to be found on the various pages of the
menu. The order they are in and/or inclusion may differ depending on the
model of the machine on which the operating terminal is installed.
Important
Depending on the cycle selected, certain commands are not dis-
played.
– “Pipe haul-off device” field:

used to activate the movement of
the haul-off device and the pipe
cleaning blow.
23510706000.tif
– Icon (300): Touch the icon to low-
er the device and touch again to lift
it.
– Icon (301): Touch the icon and
keep it pressed to drive the device
belt. Movement stops when the
icon is released.
Icon (302): Touch icon to activate pipe cleaning blow and touch it again
to deactivate it.
Zone (535): shows the immediate value of the position of the pipe haul-
off device.
– “Pipe arrival conveyor” field:

used to drive the rotation of the roll-
23510705900.tif
ers of the pipe infeed conveyor (if
present).
Icon (306): Touch the icon and
keep it pressed to activate the mo-
torised roller unit. Movement stops
when the icon is released.
– “Pipe stop device” field: used to

enable the movement of the pipe
23510717200.tif
stop device.
Icon (307): Touch the icon to raise
the device and touch it again to
lower it.
UM - 100400-09
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- 30 -
Chapter 4
ABOUT USE
– “Pipe transfer supports” field:

used to activate the movement of
the pipe supports of the bench unit.
Icon (320 - 323 - 326): Touch the
icon to raise the relative support.
Touch it again to lower the support.
Icon (321- 324 - 325 - 327 - 328):
Touch the icon to move the relative
support to the working position.
23510706100.tif
– Icon (329): Touch the icon to ac-
tivate the pipe unloading lever and
touch it again to have it return to a
235107132-00
rest position.
– “Bench movement” field: used

to raise and lower the bench.
Zone (330): touch the icon to
raise the bench. When released
the movement stops.
23510713000.gif
Zone (331): touch the icon to lower
the bench. When released the
movement stops.
– “Link” field: used to activate the

movement of the link.
Zone (332): touch the zone to
start the slow forward movement
of the link. When released the
movement stops.
23510713000.gif
Zone (333): touch the zone to start

the slow backward movement of
the link. When released the move-
ment stops.
the quick forward movement of the
link. When released the movement
stops.
UM - 100400-09

the quick backward movement of the link. When released the movement
stops.
C423510710.fm
Zone (336): touch the zone to operate the pipe reception flaps. When re-
leased the movement stops.
- 31 -
Chapter 4
ABOUT USE
Zone (347): touch the zone to operate the pipe unloading flaps. When re-
Zone (529): shows the instantaneous position of the link.
– “Oven 1 movement” field: used

to move the oven 1.
Icon (218): Touch the icon to ad-
vance the device.
Icon (346): touch the icon to disa-
235107064-00
ble the check valve of oven 1 and
touch it again to enable it.
Icon (342): touch the icon to deac-
tivate the heating of oven 1 and
touch it again to activate the heat-
ing.
Zone (504): shows the immediate value of the oven temperature.
Zone (525): shows the immediate value of the oven position.
– “Oven 1 pipe rolling” field: used

to start the pipe rolling movement
of oven 1.
Icon (345): touch the icon to lower
the rolling and touch again to lift it.
235107065-00
Icon (343): touch the icon and
keep it pressed to start the rolling
(anti-clockwise direction). When re-
(clockwise direction). When released the movement stops.
– “Chamfering unit movement”

field: used to move the chamfering
unit.
Icon (380): touch the icon to draw
back the device and touch it again
235107065-00
to move it forward.
UM - 100400-09
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- 32 -
Chapter 4
ABOUT USE
– “Oven 2 movement” field: used

to move the oven 1.
vance the device.
Icon (366): touch the icon to disa-
235107134-00
ble the check valve of oven 2 and
touch it again to enable it.
Icon (362): touch the icon to deac-
tivate the heating of oven 2 and
touch it again to activate the heat-
ing.
Zone (504): shows the immediate value of the oven temperature.
Zone (525): shows the immediate value of the oven position.
– “Pipe rolling” field: used to start

the pipe rolling movement of oven
2.
Icon (365): touch the icon to lower
the rolling and touch again to lift it.
235107069-00
(anti-clockwise direction). When re-
Icon (364): Touch and hold the
icon to open the clamp (clockwise).
Movement stops when the icon is released.
– “Market movement” field: used

to activate the movement of the
marker (device equipped with
pneumatic actuator).
Icon (380): touch the icon to with-
draw the device. Touch the icon
again to move it forward. 235107066-00
Pipe pressing unit field: used to

start the pipe pressing unit move-
ment.
Icon (382): touch icon to activate
the device and touch again to deac-
tivate it.
“Marker pen” field: used to start
the marker pen movement.
Icon (383): touch icon to activate the device and touch again to deacti-
vate it.
UM - 100400-09
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- 33 -
Chapter 4
ABOUT USE
– “Pipe clamp” field: used to open

and close the pipe clamp
Icon (400): Touch and hold the icon
to close the clamp. Movement stops
235107070-00
icon to open the clamp. Movement
stops when the icon is released.
– “E.P. chamber” field: used to

start the movement of the E-P-
chamber
keep it pressed to start the E.P.
235107071-00
chamber moving forward When re-
keep it pressed to draw back the
E.P. chamber When released the
movement stops.
Zone (529): shows the immediate value of the carriage position.
“Hydraulic drive unit” icon

Icon (410): Touch the icon to start
235107073-00
the hydraulic drive unit and touch
the icon again to stop it.
– “Flange” field: used to move the

flange.
keep it pressed to activate work-
feed of the flange. Movement stops
235107074-00

keep it pressed to activate with-
drawal of the flange. Movement
stops when the icon is released.
Icon (462): Touch the icon to un-
block the movement of the flange.
Zone (525): shows the immediate value of the flange position.
UM - 100400-09
C423510710.fm
- 34 -
Chapter 4
ABOUT USE
– “Forming carriage” field: used

to move the carriage.
Icon (408): touch and hold icon to
move carriage forward. When re-
235107075-00
Icon (409): touch and hold icon to
move carriage backward. When re-
Icon (463): Touch the icon to un-
block the movement of the car-
riage.
Icon (486): touch the icon to block the movement of the carriage.
Zone (528): shows the immediate value of the carriage position.
“Mandrel” field: used to move the

mandrel.
Icon (411): touch the icon to ena-
ble the lock/release selector on the
command console for the quick
235107076-00
coupling device of the mandrel.
Icon (412): Touch the icon to open
the segments and touch it again to
close them.
– “Ring lubrication tool” field:

used to move the tool.
vate the tool and touch it again to
deactivate it.
235107076-00
icon to activate tool rotation. Move-
ment stops when the icon is re-
leased.
Icon (448): touch the icon and keep
it pressed to activate the ring lubrica-
tion pump. After releasing the icon, the pump will stop.
– “Ring loading device” field:

used to move the ring pusher.
235107078-00
vance the pusher and touch it again

to withdraw it.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
– “Rings loader” field: used to

start the rings loader movement.
keep it pressed to raise the rings
loader. Movement stops when the
235107072-00
icon is released.
keep it pressed to lower the rings
icon is released.
– “Ring magazine belt” field:

used to move the belt.
Icon (450): touch the icon to start
the belt rotating and touch it again
235107079-00
to stop it.
Icon (451): touch the icon to draw
back the belt during the tooling of
the machine. When released the
movement stops.
Icon (452): touch the icon to advance the conveyor belt after tooling.
When released the movement stops.
– “Magazine” field: used to oper-

ate the magazine.
Icon (440): touch the icon to start
the magazine rotating and touch it
235107080-00
again to stop it.
Icon (453): touch the icon to un-
block the magazine rotating and
touch it again to block it.
– “Horizontal magazine auger”

field: used to drive the worm screw
conveyor.
235107081-00
Icon (441): touch and hold the icon

to activate worm screw conveyor
rotation. Movement stops when the
icon is released.
– “Horizontal ring magazine stop

lever device” field: used to move
the device.
235107082-00
to move ring stop device back-

wards. When released, the device
UM - 100400-09
returns to idle position.

C423510710.fm
- 36 -
Chapter 4
ABOUT USE
– “Mandrel cooling” field: used to

activate the devices of the socket
cooling system (with water).
235107086-00
vate the mandrel cooling fan and
touch it again to deactivate it.
Icon (421): Touch the icon to open
the valve that enables mandrel
cooling and touch it again to deactivate it.
– “Water pump” field: used to ac-

tivate the devices of the socket
cooling system (with water).
235107085-00
the pump and touch again to deac-
tivate it.
vate EP chamber water input valve
and touch again to deactivate it.
– “Vacuum generator” field: used

to activate the vacuum system de-
vices.
235107084-00
to activate the pump. After releas-
ing the icon, the pump will stop.
– “External pressure and cool-

ing” field: used to activate the de-
vices of the external pressure
235107087-00
circuit and socket cooling.
vate external pressure and touch
again to deactivate it.
vate discharge of external pressure
and touch again to deactivate it.
Icon (429): Touch the icon to activate differential external pressure and
touch again to deactivate it.
UM - 100400-09
C423510710.fm
- 37 -
Chapter 4
ABOUT USE
– “Vertical magazine ring grip-

per” field: used to drive the ring
gripper.
keep it pressed to raise the ring
gripper. When released the device
stops.
235107083-00
keep it pressed to lower the ring
stops.
keep it pressed to close the ring
stops.
keep it pressed to open the ring gripper. When released the device stops.
Icon (458): touch the icon and keep it pressed to rotate the ring gripper
in the direction of the magazine. When released the device stops.
Icon (459): touch the icon and keep it pressed to rotate the ring gripper
in the direction of the conveyor belt. When released the device stops.
– “Rings loader tooling” field:

used to position the loader in the
right position for tooling.
235107089-00
keep it pressed to lower the rings
icon is released.
keep it pressed to raise the rings
loader. When released the movement stops.
– “Filter cleaning” field: used to

clean the filter.
235107088-00
the filter cleaning valve and touch

again to deactivate it.
the filter cleaning shut-off valve and
touch again to deactivate it.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
– “Pipe cooling” field: used to

cool (air) the pipe socket.
235107144-00
the fan and it touch again to deacti-
vate it.
vate the closing of the pipe cooling
circuit and touch it again to activate
the opening of the pipe cooling cir-
cuit.
4.5. RECIPE MANAGER MENU

A program can be created, viewed, modified, saved and cancelled with
this function.
This function allows to load a previously stored program, edit it and over-
write it or store it with a new code.
The icons on the various pages of the "Programs" menu have the same
function and a similar identification number compared with those in the
"Process" menu (For further information, see 4.3. - "Process display and
editing menu").
Their order and/or presence can be different depending on the machine
model where the operator’s terminal is installed.
The operations available via this menu are described below.
Program selection
1 – Touch the icon (27) to display
the program index stored in the
memory of the operating terminal.
235107120-00
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
2 – Touch the icons (30-32) to scroll

the list of programs.
3 – Touch the name of the desired
A
recipe on the display. The identifi-
cation number of the recipe select-
ed is displayed in area (A).
4 – Touch the icon (31) to load the
selected program.
235107121-00
5 – The name of the selected pro-
gram appears in zone (24).
23510712200.tif
6 – Zone (25): shows the name of
the program in use.
Editing programs
1 – Select the program required (See "Program selection").
2 – Edit the production parameters.
3 – Touch the icon (26) to save the
changes.
23510712300.tif

play.
Icon (20): touch icon to confirm the
modifications.
23510712600.tif
Icon (21): touch icon to exit without

saving.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
Loading programs
Important
The current program remains loaded in the PLC memory (even
when the machine is switched off) until another program is loaded
or the PLC buffer battery wears out.
2 – Touch the icon (29) to load the
selected program into the PLC’s
memory and to activate it.
23510702500.tif
This control is only enabled with the
mode sector in position (0-MAN).
Deleting programs
2 – Touch the icon (28) to delete the
selected program.
23510712400.tif
play.
Icon (22): Touch the icon to delete
the selected program.
Icon (23): touch the icon to exit
without performing any opera-
tions.
Important
23510712700.tif
When a parameter program is

deleted, the corresponding line
in the list remains blank.
UM - 100400-09
C423510710.fm
- 41 -
Chapter 4
ABOUT USE
Transfer of programs on removable device

The entire recipe index may be transferred from the operating terminal to
a removable memory card and vice versa.
Important
This should be done very carefully as the software transfers the
data automatically without prompting you to confirm the operation.
1 – Insert a compatible removable memory card into the relative port on
the operating terminal.
2 – Touch the icon (27) to access
the "Program List" menu.
40025105700.tif
3 – Touch icon (34) to copy the rec-
ipe index stored in the memory of
the display onto the removable
memory card.
4 – Touch icon (35) to overwrite the
recipe index stored in the memory
of the display with the index con-
tained on the removable memory
card.
235107121-00
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
4.6. MACHINE PARAMETERS MENU

Touch icon (6) to access the setup
pages of the equipment (language,
date, time, etc.).
The list only includes commands
for use by the operator. The order
they are in and/or inclusion may
differ depending on the model of
the machine on which the operat-
ing terminal is installed.
– “Select language” field

Icon (310): Touch the icon a num-
ber of times to select the language.
Important
The text on all the pages is
changed to the language select-
ed instantaneously.
– “Date and time” field

Touch the parameter on the dis-
B
play and use the "numeric keypad"
to key in the value (see 4.2. - "How
to use the operator’s terminal").
Zone (312-313-314): Current date
(00/00/0000 - day/month/year)
Zone (315-316): Current time
(00:00 - hour:minutes)
Icon (317): touch the icon to store
the data set. Zone (B) shows the
date and the time set.
– “Contrast adjustment” field

Icon (318-319): Touch the icons to
increase or reduce the contrast on
the display.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
– “Icon identification number”

vate the visualisation of the icon
identification number.
visualisation of the icon identifica-
tion number.
– “Change Password” field: used

to set a new password to access to
the other programming pages and
display of operation parameters of
the machine.
enter the current password.
enter the new password.
repeat the introduction of the new password.
Icon (333): touch icon to confirm the modifications.
– “Access to protected pages”

icon: to access the other pages to
programme and display the operat-
ing parameters of the machine.
Icon (311): Touch icon to enter the
password and to access the hid-
den pages.
In the hidden pages you can mod-
ify the basic parameters for the operation of the machine.
Caution - Beware
The following parameters may only be modified by a technician au-
thorised by the manufacturer. Unauthorised tampering may com-
promise the functions and safety of the machine.
For more information, contact the manufacturer’s support service.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
1 – To access the hidden pages,

touch icon (311).
The display will show the "Pass-
word Enter" field.
2 – Touch the display in area (A).
An "Alphanumeric keyboard" is dis- A
played.
3 – Enter the password with the

keypad and touch "Enter" (M) to
confirm.
4 – Touch button "Clear" (N) in or-
P
der to delete the last entered value,
or button "Cancel" (P) in order to N
cancel the operation.
M
Important
The hidden pages can be ac-
cessed if the password is cor-
rect.
Repeat the procedure from point 2 if the password is incorrect.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
4.7. DISPLAY ALARMS MENU

This function shows information needed to find the cause of the alarm
condition and the controls to acknowledge the alarm.
1 – Touch the icon (7) to access the
"Active alarms" menu.
The "ACTIVE" alarms page shows
the alarms currently activated, in
chronological order starting from
the last one, and classified as
shown below.
– Active alarm: highlighted by a
black box.
It may reset automatically, or you
can reset it by pressing the indica-
tor light button to deactivate the si-
ren on the machine command
console.
– Reset alarm: the alarm is no
longer active (the cause has been 40027708200.tif
resolved), but is not acknowledged.

Highlighted by a grey box. To perform the acknowledgement procedure,
see "Acknowledgement of an alarm".
To have more detailed pieces of information in order to solve the irregu-
larity, simply touch the description of the involved alarm.
The display shows icon that stands for the area in which the irregularity
occurred and, in case, includes the abbreviations of the electrical compo-
nents that may have caused it.
To identify the signalled component in a clearer way, see the wiring dia-
gram.
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
Acknowledgement of an alarm
Important
Acknowledgement of an alarm confirms that the message has been
read, but does not mean that the problem that caused the alarm has
been corrected.
2 – Touch the icons (700-702) to

scroll through the list and touch the
name of the required alarm on the
display.
40027708200.tif
The "LOG" alarms page shows the

alarms resolved and acknowl-
edged, in chronological order start-
ing from the last one.
Alarms are automatically moved
from the "ACTIVE" page to the
"LOG" page when they have been
both resolved and acknowledged.
40027708300.tif
UM - 100400-09
C423510710.fm
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Chapter 4
ABOUT USE
4.8. ALARM CONDITIONS

Alarm conditions are signalled by a buzzer, a visual signal and a mes-
sage on the display, which always appears in area (A2) (See 2.1. - "Gen-
eral description of the operating terminal").
The audible alarm can be muted (see the machine manual), while the vis-
ual alarm remains active as long as the alarm condition persists.
The alarm message is displayed from the time the event was detected
until the event is removed and the operator has acknowledged it.
To display and acknowledge the alarms, see the 4.7. - "DISPLAY alarms
menu" paragraph.
Table 4.1: Alarm messages
Alarm code Alarm Machinery status Note
An emergency button has been pressed or an

NO POWER TO emergency circuit device has been activated.
A000 Safety conditions
AUXILIARIES Remove the conditions that caused the
emergency and reset the machine.
The air pressure in the circuit is low. The
machine stops when a movement driven by a
A001 AIR PRESSURE Pause cycle pneumatic actuator interrupts the work cycle.
Stop the machine and restore the correct
functioning of the pneumatic system.
The alarm indicates that the water pressure in
A002 WATER PRESSURE No change
the water circuit is insufficient.
An electric motor thermal cut-out has tripped.
The machine stops when the movement
controlled by the faulty electric motor
A003 MOTOR OVERLOAD Pause cycle interrupts the work cycle. Wait a few minutes
and reset the thermal cut-out. If the problem
persists, find the cause using the wiring
diagram.
The inverter for moving the carriage is faulty.
A004 INVERTER Stop cycle Restore safety conditions and check it is
operating correctly.
The alarm indicates that the guards were
A006 GUARD BY-PASS No change excluded ("safety panel bypass" selector in
position 1).
BELLING MACHINE
The production level specified in the current
A007 PRODUCTION LEVEL No change
program has been reached.
REACHED
The alarm signals that the pipe coming from
A010 UNCUT PIPE Pause cycle
the upstream machine has not been cut.
The line has been put out of production
UM - 100400-09
PRODUCTION OFF- (deactivated).

A012 No change
LINE To activate the line see page 2 "View and
modify processes menu".
C423510710.fm
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Chapter 4
ABOUT USE
The loading flange tooling device has not

been properly positioned. Stop the machine
LOADING FLANGE
A013 Stop cycle and unlock the flange. If the flange is un-
TOOLING
locked, restore the correct operation of the
control sensor.
The rings belt is not properly positioned, the
A014 BELT TOOLING Stop cycle automatic operating cycle cannot be started,
stop the machine and check.
The alarm indicates a fault with the pipe haul-
A016 PIPE NOT IN POSITION No change
off device.
The temperature of the ovens is lower or
higher than the set value. Stop the machine
OVEN 1
A020 No change and reset correct oven operation. If
TEMPERATURE
necessary, consult the temperature regulator
user manual.
The pipe heating process in the oven 1 was
interrupted. Press the button again to restart
A021 OVEN 1 SUSPENDED Pause cycle
the pipe heating cycle from where it was
interrupted.
The temperature of the ovens is lower or
higher than the set value. Stop the machine
OVEN 2
A030 No change and reset correct oven operation. If
TEMPERATURE
necessary, consult the temperature regulator
user manual.
The pipe heating process in the oven 2 was
interrupted. Press the button again to restart
A031 OVEN 2 SUSPENDED Pause cycle
the pipe heating cycle from where it was
interrupted.
The forming organs have exceeded the
minimum safety distance. Check the
COLLISION parameters set in the operating cycle menu;
A040 Stop cycle
EMERGENCY if necessary, check the operation of the
encoders controlling the position of the
forming organs
The temperature of the oil is higher than the
A041 OIL TEMPERATURE No change
correct value with normal operation. Check.
The oil filter in the control unit is clogged.
A042 INPUT OIL FILTER No change
Stop the machine and replace the filter.
DISCHARGE OIL The oil filter in the control unit is clogged.
A043 No change
FILTER Stop the machine and replace the filter.
UM - 100400-09
LOW OIL LEVEL IN The oil level in the hydraulic control unit is
A044 No change
HYDRAULIC UNIT low. Check
C423510710.fm
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Chapter 4
ABOUT USE
The mandrel locking device was not

activated. The automatic operating cycle can
not be activated. Stop the machine and lock
A045 MANDREL LOCKED Stop cycle
the mandrel. When the mandrel is locked,
restore the proper operation of the control
sensor.
The pipe detection photocell detects the pipe
before the forming cycle begins and/or after
PIPE IN FORMING
A046-A047 Pause cycle the forming cycle is completed. To release
STATION
the block, perform the necessary movements
with the machine in "manual cycle".
There are not the proper conditions to carry
out the belling phase because the pipe
moved too much backward or there is no
A048 PIPE TOO FAR No change
pipe. The carriage returns to its starting
position, the pipe is unloaded and the
machine waits for the next pipe.
Air pressure in the forming chamber is too
FORMING CHAMBER
A050 No change high. Halt the machine and reset correct
AIR PRESSURE
pneumatic system function.
The pipe forming process has been
A052 SUSPENDED FORMING Pause cycle
suspended.
This alarm will turn on when the forming
A053 FORMING TIME-OUT No change
process has not been completed.
The forming carriage reached the limit
switches without achieving the set quote; the
carriage returns to the initial position and the
CARRIAGE LIMIT
A054 Pause cycle machine waits for the following pipe. This
SWITCH
alarm is activated when the "carriage forward
position" has not been correctly set, or the
pipe is badly positioned.
The carriage has reached the reverse limit
switch in manual mode.
CARRIAGE In order to move the carriage using the
A056 BACKWARD LIMIT No change manual controls, switch the mode selector to
SWITCH
“0”, and then back to " "
The alarm indicates that the rings are finished

A060 EMPTY STORE Pause cycle
and the ring store must be loaded.
The alarm indicates that the rings are almost
A061 RINGS LOW No change
UM - 100400-09
finished and the ring store must be loaded.

A063-A064- The alarm indicates that the ring has not been
NO RING Pause cycle
A065 fitted correctly in the feed hopper.
C423510710.fm
The level of the ring lubrication oil is low.

A066 RINGS OIL LEVEL No change
Check.
- 50 -
Chapter 4
ABOUT USE
The link cannot evacuate all the pipes.

A070 LINK OVERLOAD Pause cycle Access the inside of the machine and free the
link.
B...
A device has failed, the machine stops when
BR... the movement commanded by the failed
K... device interrupts the operating cycle. Check if
actuator relative to the indicated output is
M...
A... Pause cycle malfunctioning, or check that the indicated
R... component is functioning and correctly
S... positioned.
U... Refer to the electrical diagram to identify the
function of the component indicated.
Y...
When various alarms go off simultaneously, the most serious or

dangerous alarm determines the machine status.
When the machine is in "CYCLE PAUSE" mode, if the cause of the
alarm is automatically solved, the operating cycle re-starts again af-
ter stopping the alarm.
Progression:
NO CHANGE
PAUSE CYCLE
STOP CYCLE
SAFETY CONDITIONS
4.9. REPLACING THE PLC DISPLAY BATTERIES
Important
Replace the battery every 3 years in order to make sure all the con-
figuration parameters memorised in the PLC remain in memory.
All the information regarding the procedure for replacing the battery is
contained in the enclosed booklet UM_A00100.
UM - 100400-09
C423510710.fm
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C423510710.fm UM - 100400-09
Chapter 4
ABOUT USE
- 52 -
(REPLACING BATTERIES)
READ THIS MANUAL

BEFORE USE
OPERATING GUIDE EN
UM - A00100-01
UM - A00100
Instructions translated 11 - 2014 Rev. 01
from the original
C023522500.fm
Machine No.
language
1507903
(REPLACING BATTERIES)
SICA S.p.A.
UM - A00100-01

C.F./P.Iva IT00084440395
Tel. ++39/0544/88711 - Fax ++39/0544/81340
C023522500.fm
Customer Service
Tel. ++39/0544/88774 - Fax ++39/0544/88821
SUMMARY
1 GENERAL INFORMATION......................... 3
1.1 Purpose of the manual................................. 3
4 ABOUT USE................................................ 5
4.1 Replacing the PLC DISPLAY
batteries (PP65) ...........................................5
batteries (PP41) ...........................................5
batteries (PP35) ...........................................6
batteries (PP420) .........................................6
batteries (PP520) .........................................7
4.6 Replace the PLC batteries inside the rotor .. 8
UM - A00100-01
IN23522500.fm
-1-
ANALYTICAL INDEX
M
Manual, aim of (3)
P
R
Replace the PLC batteries inside the rotor (8)
Replacing the PLC DISPLAY batteries (PP35) (6)
UM - A00100-01
IN23522500.fm
-2-
Chapter 1
GENERAL INFORMATION 1
1.1 PURPOSE OF THE MANUAL
Important
This manual, which is attached to the Operating Guide of the Touch
Screen Terminal, was made by the manufacturer to describe only
the parts that differ from the manual of the Standard machine.
Important
All information relating to the SAFETY and USE of the machine is in
the Touch Screen Terminal user manual to which this manual re-
fers.
– As well as adopting an appropriate utilization technique, the recipients
of the information must read and strictly apply them.
– This information is supplied by the manufacturer in its own language
(Italian) and may be translated into other languages to satisfy statutory
and/or sales needs. A little time dedicated to the study of this information,
will permit the user to avoid health and safety risks to personnel and eco-
nomic loss.

NAL INSTRUCTIONS".
– In case in which, in this manual, there is additional information regard-
ing the actual setup of the equipment, it does not interfere with the read-
ing.
– Keep this manual for the entire duration of the equipment useful life in
a well known and easy to access place, available for reference any time
the need should arise.
– In order to highlight some parts of the text which are especially impor-
tant or to indicate some important specification, a few symbols, whose
meaning is described hereunder, have been adopted.
Danger - Warning
Indicates situations involving great hazard risks which, if over-
looked, could put people’s health and safety in great danger.
Caution - Beware
UM - A00100-01

C123522500.fm
Important
not be overlooked.
-3-
Chapter 1
GENERAL INFORMATION
UM - A00100-01
C123522500.fm
-4-
Chapter 4
ABOUT USE 4
4.1 REPLACING THE PLC DISPLAY BATTERIES

(PP65)
1 – Open the hatch that houses the
operator panel.
2 – Remove the battery cover (A)
using a screwdriver.
3 – Change the battery (B) (Model
RENATA CR2477N).
Important
Replace the battery every 3
years in order to make sure all
the configuration parameters
memorised in the PLC remain in
memory.
4 – Put in the new battery, taking
care to place the red tab behind it A B
as shown in the photo.
235064020-00

(PP41)
operator panel.
RENATA CR2477N).
Important
A
memory.
care to place the red tab behind it B
UM - A00100-01
235225001-00
C423522500.fm
-5-
Chapter 4
ABOUT USE

(PP35)
operator panel.
RENATA CR2477N).
Important
memory.
B
care to place the red tab behind it
as shown in the photo. A
235225002-00

(PP420)
operator panel.
RENATA CR2477N).
Important A
memory.
as shown in the photo. B
UM - A00100-01
235225003-00
C423522500.fm
-6-
Chapter 4
ABOUT USE

(PP520)
operator panel.
using a screwdriver. A
RENATA CR2477N).
Important
memory.
B
235225004-00
UM - A00100-01
C423522500.fm
-7-
Chapter 4
ABOUT USE
4.6 REPLACE THE PLC BATTERIES INSIDE THE

ROTOR
1 – Start the machine in “manual” mode.
2 – Use the manual controls to make the work area on the rotor easily ac-
cessible.
3 – Turn the mode selector switch (6) to “0”.
4 – Extract the key of selector.
5 – Open the moveable guard (A).
6 – Turn the main cut-off switch (1) to "O" (OFF) to disconnect the elec-
trical power supply,
7 – Deactivate the pneumatic supply (see use and maintenance manual).
8 – Open door (B).
9 – Remove the cover (C) of the electrical box.
10 – Remove the battery cover (D).
11 – Change the battery (E) (Model RENATA CR2477N).
Caution - Beware
When the operations have finished, check that no tools, rags or oth-
er materials have been left near moving parts or in hazardous areas
before restarting the machine.
12 – Put back the cover (C).
13 – Close door (B).
14 – Close the mobile guard (A).
15 – Restart the machine in "manual" mode to make sure everything is
operating correctly (see use and maintenance manual ).
Important
Replace the battery every 3 years in order to make sure all the con-
figuration parameters memorised in the PLC remain in memory.
UM - A00100-01
C423522500.fm
-8-
Chapter 4
ABOUT USE
1 6
E
B
A
C
235064027-00
UM - A00100-01
C423522500.fm
-9-
CATALOGO RICAMBI
SPARE PARTS CATALOGUE
CR - 1507903
05 - 2015 Rev. 01
N. Macchina - Machine No.

1507903
La Ditta SICA S.p.A. si riserva di agire con ogni mezzo consentito dalla legge contro chi riproduce o mostra a terzi senza la sua
autorizzazione scritta questo documento e tutto quanto in esso contenuto.
Le descrizioni e le illustrazioni contenute nel presente manuale si intendono non impegnative ferme restando le caratteristiche del tipo
di macchina descritta. Il Costruttore si riserva il diritto di apportare tutte le modifiche ritenute necessarie per il miglioramento del
prodotto, in qualunque momento e senza impegnarsi ad aggiornare il contenuto del presente manuale.
Il presente manuale deve essere conservato per tutta la durata di vita della macchina in luogo
accessibile a tutto il personale addetto al funzionamento e manutenzione della macchina.
This manual must be stored for the entire life of the machine, in a location that is accessible to all
machine operators and maintenance staff.
CATALOGO RICAMBI
SPARE PARTS CATALOGUE
SICA S.p.A.
C.F./P.Iva IT00084440395
Tel. ++39/0544/88711 - Fax ++39/0544/81340
Customer Service
Tel. ++39/0544/88774 - Fax ++39/0544/88821
GRUPPO FINECORSA E1G07050
LIMIT STOP UNIT 00
N. CODE DENOMINAZIONE DENOMINATION

1 KF100450 FINECORSA LIMIT SWITCH
2 D34K6040 STAFFA BRACKET
3 D1G07042 ASTA ROD
4 D3470500 PIASTRA PLATE
5 D3470520 REGOLATORE REGULATOR
* Ricambio consigliato - Advised spare parts

4
2
1
5
GRUPPO FINECORSA E1G07050

LIMIT STOP UNIT 00
GRUPPO CASSETTA E1079401
BOX UNIT 00
N. CODE DENOMINAZIONE DENOMINATION

1 FM0I0010 RADIATORE ARIA COOLER AIR
2 E1079400 GRUPPO CASSETTA BOX UNIT
* Ricambio consigliato - Advised spare parts

2
GRUPPO CASSETTA E1079401

BOX UNIT 00
SYSTEM LIST
Distinta Codice : C1FHG000 - GR.IMPIANTO PNEUM. UNIBELL1 200EL
Numero Livelli : 3
POS CODE QTY DESCRIPTION TYPE MANUFACTURER

1 E1F2G004 1
1.1 FP040721 4 SOLENOID VALVE 5/2-CD01 24V dc 5763510620 BOSCH
1.2 FP0C0030 8 FLOW CONTROL VALVE 1/4-8 454080 SISTEM PNE.
1.3 FP0C0140 4 FLOW CONTROL VALVE G1/4-10 454100 SISTEM PNE.
1.4 FP0D0226 5 PLATE FOR 1 VALVE CD01 1825504023-G1/4 BOSCH
1.5 FP0D0227 1 END-PLATES BATTERY CD01-G3/8 1825504031-G3/8 BOSCH
1.6 FP0D0233 1 1825504033 BOSCH
1.7 FP130210 4 SILENCER 2901-3/8 2901-3/8 CAMOZZI
1.8 L7110020 4
1.9 L8121010 5
2 E1FHG001 1
2.1 FM0P0020 2 AIR TANK 25lt/16bar S.E.A.
2.2 FP040721 5 SOLENOID VALVE 5/2-CD01 24V dc 5763510620 BOSCH
2.3 FP040727 1 SOLENOID VALVE 5/2 5725550220 BOSCH
2.4 FP090210 2 MANOMETER 0-6 bar/psi DN 40 M3B-40 0-6 bar/psi FIMET
2.5 FP0B0040 4 PRESSURE REGULATOR 0.5-10 bar NL2-G1/4 0821302401 NL2-G1/4 BOSCH
2.6 FP0C0140 6 FLOW CONTROL VALVE G1/4-10 454100 SISTEM PNE.
2.7 FP0C0150 4 FLOW CONTROL VALVE NG12 1/2 0821201006 BOSCH
2.8 FP0C0160 2 FLOW CONTROL VALVE NG6.1/4 0821201011 BOSCH
2.9 FP0D0226 5 PLATE FOR 1 VALVE CD01 1825504023-G1/4 BOSCH
2.10 FP0D0227 1 END-PLATES BATTERY CD01-G3/8 1825504031-G3/8 BOSCH
2.11 FP0D0228 1 PLATE FOR 1 VALVE CD01-G1/4 1825504016-G1/4 BOSCH
2.12 FP0D0233 1 1825504033 BOSCH
2.13 FP0F0040 4 RAPID OUTLET VALVE G1/4 0821002003-G1/4 BOSCH
2.14 FP0F0060 1 UNIDIRECTIONAL VALVE G1/2 0821003003-G1/2 BOSCH
2.15 FP0F0262 2 UNIDIRECTIONAL VALVE G1/2 0821003028-G1/2 BOSCH
2.16 FP0F0268 4 RAPID OUTLET VALVE G1/2 5735040300 G1/2 BOSCH
2.17 FP0H0050 1 2-WAYS COCK 3/4 F-F 1720 F-F 3/4 STIMA
2.18 FP0H0060 2 2-WAYS COCK F-F 1/4 3930 F-F 1/4 cromata STIMA
2.19 FP0M0070 1 ADJUSTABLE PRESSURE SWITCH 1/8 0880300 NORGREN
2.20 FP0N1057 1 R480309005 REXROTH
2.21 FP0N5040 2 NUT 1829234070 NL2-M30x1.5 BOSCH
2.22 FP0N5205 1 R412007371 AS3-MBR-X000-W04 BOSCH
Utente: ezavoli Pag. 1 di 2 Data: 25/08/2015

SYSTEM LIST
Distinta Codice : C1FHG000 - GR.IMPIANTO PNEUM. UNIBELL1 200EL
Numero Livelli : 3

2.23 FP0N5212 1 4-WAYS DISTRIBUTOR -G1/2 R412007251 AS3-DIS-G012-NC3 BOSCH
2.26 FP130301 4 SILENCER 1/2BSP B05-0121005 1/2BSP
2.27 L8121010 4

SYSTEM LIST
Distinta Codice : C1FHH000 - GR.IMPIANTO IDRICO UNIBELL1 200EL
Numero Livelli : 3

1 FP0F0180 1 UNIDIRECTIONAL VALVE 1/4 ART.VFU 1/4 STIMA
2 FP0H0030 2 2-WAYS COCK F-F 3/8 3930 F-F 3/8 cromata STIMA
3 FP0H0050 4 2-WAYS COCK 3/4 F-F 1720 F-F 3/4 STIMA
4 FP0H0250 1 2-WAYS COCK 1/2 F-F 1720 F-F 1/2 STIMA
5 FP0H0640 2 3-WAYS COCK 1/4" F-F-F 6700 F-F-F 1/4" MOVIM. L STIMA
6 HG210050 4
7 L7110030 4
8 L8010060 4
9 L8081060 4
10 L8120040 8 2611-3/8 CAMOZZI
11 L8260020 2 ART.5150-1/4 CAMOZZI
12 L8270020 2 ART.5051-1/4 CAMOZZI
13 L8280010 1 SAFETY VALVE G3/8

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UNIBELL1 200 LE

(AUTOMATIC BELLING MACHINE)

READ THIS MANUAL

ORIGINAL INSTRUCTIONS N. Machine

2.1. Machine general description.......................11 4 INFORMATION ON HANDLING AND

2.11. Pneumatic devices......................................34 4.11. Pneumatic connection.................................76

1.1. PURPOSE OF THE MANUAL

1.2. TYPES OF OPERATOR

extrusion lines, including belling machines. He is responsible for

1.3. MANUFACTURER AND MACHINERY

1.4. TECHNICAL SERVICE REQUEST

1.5. TERMS AND DEFINITIONS

1.6. ENCLOSED DOCUMENTATION

2.1. MACHINE GENERAL DESCRIPTION

Pipe unloading area

Belling and socket cooling area

– The heat-forming process is described, according to the type of socket,

– The machine can be programmed to bell pipes of various lengths but

Extrusion axis Belling machine Planetary

– Upon completion of machine installation, before starting extrusion line

2.2. CONSTRUCTIVE CONFIGURATION OF THE

2.3. ACCESSORIES AVAILABLE UPON REQUEST

2.4. EQUIPMENT SUPPLIED

Equipment for belling smooth sockets

2.5. OPERATING CYCLE

Pipe infeed phase

Belling preparation cycle Pipe unloading cycle

2.6. BELLING CYCLE PROCESS

2.7. BELLING PREPARATION CYCLE

2 – The photocell (W) detects the

3 – Beam 1 lifts the pipe and places

4 – The rolling clamp (D) lowers

5 – Oven advances, wrapping the

6 – Once the pipe heating has fin-

7 – Beam 2 lifts the pipe and places

8 – The clamp (F) locks the pipe in

2.8. "SMOOTH MANDREL" BELLING CYCLE

1 – The forming carriage (G) moves

2 – The "COOLING" timer starts

3 – Once the time of the "COOL-

4 – The clamp (F) opens.

2.9. PIPE UNLOADING CYCLE

2 – The photocell (W) detects the

3 – Beam 1 lifts the pipe and places

4 – Beam 2 lifts the pipe and places

5 – The pipe is unloaded by the ma-

2.10. ELECTRIC DEVICES

Table 2.2: Electric devices

1 Photocell detects the presence of the pipe in the belling unit.

detects the "closed" position of the protective mobile guard in the

3 Sensor detects the "closed" position of the pipe clamp.

4 Sensor detects the "open" position of the pipe clamp.

5 Sensor detects the "back" position of the forming carriage.

6 Sensor detects the "forward" position of the forming carriage.

Table 2.2: Electric devices

detects the "closed" position of the belling cycle protective guard to

9 Motor enables the movement of the forming carriage.

10 Motor operates the fan

Table 2.3: Electric devices