FT1555-BM230 Bench Mount Hose Capping System
Product Information:
| Product Name | Danfoss FT1555-BM230 Bench Mount Hose Capping System |
|---|---|
| Intended Use | The FT1555-BM230 is intended to only shrink CapSeal Capsules onto a hose or tube fitting. Applications other than intended use may void warranty. |
| Packaging | The CapSeal Machine is packed in cardboard for protection during transportation. Remove all packaging materials before usage. Dispose or recycle all packaging materials in accordance with the local regulations. |
| Safety Precautions | The following precautions must be followed when using the FT1555-BM230. Failure to follow warnings and fully understand the operation of the FT1555-BM230 could cause serious injury to the operator or other personnel and may void warranty. |
Product Usage Instructions:
- Before using the FT1555-BM230, read the operation instructions
and take care of the safety precautions as indicated. - Wear safety glasses when operating the FT1555-BM230.
- Never operate the unit without safety cover(s) and heat guard
removed. - Ensure that routine checks and preventive maintenance are
completed before using the system. If any part of the system is
known or suspected to be defective or wrongly adjusted, do not use
the system until a repair has been made. - Avoid touching the areas of the machine housing around the Air
Knife/Heat Guard, as these surfaces are hot and can cause burns.
Let the machine housing surfaces cool down before touching external
surfaces of the machine. - Do not put your fingers or hand in the opening of the Air Knife
to avoid the risk of burning. - Keep the work area around the FT1555-BM230 clean and dry at all
times. - Only insert the ends of hose or tube assemblies with a CapSeal
Capsule into the Air Knife. Do not place any other objects into the
Air Knife.
Operator’s Manual
Danfoss FT1555-BM230 Bench Mount Hose Capping System
Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Table of Contents
Intended Use …………………………………………………………………………………………………………………..3 Packaging ……………………………………………………………………………………………………………………….. 3 General ……………………………………………………………………………………………………………………………. 3 Safety ………………………………………………………………………………………………………………. 3 Important Information …………………………………………………………………………………………………. 3 Description of safety symbols in this manual ……………………………………………………………3 Safety Symbols on the machine …………………………………………………………………………………. 4 Safety Precautions ………………………………………………………………………………………………………….4 Residual Risks ………………………………………………………………………………………………………………….4 Description and Operating Procedures ………………………………………………………….. 5 Product Views (FRONT/ BACK/ SIDE) ………………………………………………………………………….. 5 Features & Benefits ……………………………………………………………………………………………………….. 5 Installation ……………………………………………………………………………………………………………………… 6 Operating procedures ………………………………………………………………………………………………….. 6 Capsule Application Process ……………………………………………………………………………………….. 7 Specifications …………………………………………………………………………………………………………………. 8 Machine Plate ………………………………………………………………………………………………………………… 9 Maintenance …………………………………………………………………………………………………… 10 Air Filter maintenance ………………………………………………………………………………………………….. 10 Troubleshooting ……………………………………………………………………………………………… 11 Repairs ……………………………………………………………………………………………………………..11 Advised Spare parts ……………………………………………………………………………………………………… 11 Modifications …………………………………………………………………………………………………………………. 13 Disposal ……………………………………………………………………………………………………………………………13 RoHS ………………………………………………………………………………………………………………………………… 13
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Intended Use
The FT1555-BM230 is intended to only shrink CapSeal Capsules onto a hose or tube fitting. Applications other than intended use may void warranty.
Packaging
The CapSeal Machine is packed in cardboard for protection during transportation. Remove all packaging materials before usage. Dispose or recycle all packaging materials in accordance with the local regulations.
General
When the machine is delivered, check the equipment for possible transport damage and that all components are included.
Included Contents: · CapSeal System FT1555-BM230 · CE manual · FT1555-SMP (Small Magnetic Puck) · FT1555-LMP (Large Magnetic Puck)
Safety
Important Information
! Before attempting to use the FT1555-BM230, read, understand, and know all the safety information in this chapter. If you do not follow all the warnings and procedures in this manual, it could lead to serious injury to yourself or others. This CapSeal System was designed with safety in mind and includes features to help prevent injury and damage. This manual is intended to help you operate the units in a safe manner. The operator / user is a person who physically interacts with the unit and/or the unit’s control systems. In this manual an operator / user includes a person who cleans the machine. It is your responsibility to operate this system
in accordance with all the safety instructions and procedures in this manual and with all other safety procedures in your workplace. It is the user’s responsibility to make sure that the system is correctly installed, configured, commissioned, operated, serviced, and maintained so that such actions are only carried out by people who have been properly trained for those tasks. It is also the user’s responsibility to make sure that the machine is only used in full accordance with laws – and regulations, which have the force of law – in the jurisdiction in which the machine is installed.
Description of safety symbols in this manual
Safety and Warning signs are attached to the machine to give safety information. All Safety/Warning signs are repeated and usually further explained in this manual.
Mandatory: Read User Manual before using this system. Use eye-protection Caution! Burning hands or fingers when entering Air Knife
! Caution! General warning sign
Caution! Hot surface Caution! Electrical hazard
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Safety Symbols for the UC-CSS-203V-AK
HOT SURFACE
HOT SURFACE
DO NOT PLACE FINGERS IN AIR KNIFE OPENING
CAUTION ELECTRICAL HAzARD
DO NOT PLACE FINGERS IN AIR KNIFE OPENING
Safety Precautions
The following precautions must be followed when using the FT1555-BM230. Failure to follow warnings and fully understand the operation of the FT1555-BM230 could cause serious injury to the operator or other personnel and may void warranty.
Before starting to use the FT1555-BM230 read the operation instructions and take care of the safety precautions as indicated.
Safety glasses are mandatory when operating the FT1555-BM230
The unit is never to be operated without safety cover(s) and heat guard removed.
! Do not use the system until you are sure that the routine checks described have been completed and that the routine preventive
maintenance program is up-to-date. If any part of the system is known (or suspected) to be defective or wrongly adjusted do not use the system until a repair has been made. Operation of the system with defective or wrongly adjusted components could create safety hazards. This could lead to serious personal injury.
Do not touch the areas of the machine housing around the Air Knife/ Heat Guard, as these surfaces are hot and can cause burns. Let the machine housing surfaces cool down before touching external surfaces of the machine.
Do not put your fingers or hand in the opening of the Air Knife, risk of burning fingers or hand.
*Be sure to keep the work area around the FT1555-BM230, clean and dry at all times.
Do not place any objects into the Air Knife other than ends of hose or tube assemblies with a CapSeal Capsule.
Residual Risks
Hazardous Situation The Air Knife will become hot and could cause burns to the skin Burning fingers at operating temperature in the Air Knife FT1555-BM230 176°C 350°F
Avoiding Do NOT touch while machine is in operation or immediately after use, allow to cool.
Do NOT stick fingers into the Air Knife while in use.
Warning Symbol
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Description and Operating Procedures
Product Views (Front / Back / Side)
Features & Benefits
· Applies heated air to shrink CapSeal Capsules onto fitting ends · Magnetic Puck holds the Capsule onto the fitting for a perfect
in less than one second
seal during the shrinking process (Small 40mm / Large 64mm)
· Designed for CapSeal Capsules from 14mm ID through 80mm · Magnetic Puck pulls the swivel nut forward on 90° and 45°
ID
fittings for easy insertion into the Air Knife for capsule shrinking
· Works with fitting hex sizes from 10mm through 78mm or any · Heating unit is thermocouple protected against overheating. other shape fitting within the size limitation of the capsule.
· The Air Knife with heat guard has a 110mm center opening that allows multiple assembly ends to shrink at once with use of the Magnetic Pucks.
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Installation
· Position the machine in a clean, dry, well ventilated area and away from any combustible materials.
· Keep a clear perimeter of 0.3m (12″) at both sides and 0.6m (24″) at rear of machine.
· Do not place anything on top of this machine.
· Attach Air Knife/ Heat Guard to heatgun nozzle, using allen wrench key size (3/16″ or 4.5mm)
· Tampering with cord or socket may cause electrical issues and void warranty.
· Connect the power cord to the correct electrical socket, make sure the Power On/Off Switch on the CapSeal System is in the Off position. (L6-15 NEMA twist lock)
Operating Procedures
! Check the area around the machine and make sure that
everything is clear, clean and dry before turning the FT1555-BM230 on.
· Set the Power On/Off switch in the on position. The Power switch will light up green. From a cold start the machine will take 8 minutes to reach the optimal sealing temperature. (Consult Chart Below)
· Place the CapSeal Capsule over the fitting of the hose or tube assembly. Place small or large puck onto the end fitting to ensure no space between end fitting and capsule. Be sure capsule is not extended over the edge of Puck for even heat distribution
· Slowly insert fitting through the Air Knife with a forward motion allowing the fitting to pass through the Air Knife. Then with a backwards motion pull the fitting out of the Air Knife.
· Remove magnetic puck and inspect capsule to confirm that it is shrunk securely onto the fitting
! Do NOT leave the FT1555-BM230 unattended when in use.
Machine Warm-Up time from cold start
WARM-UP TIME (MIN) 1 2 3 4 5 6 7 8 9 10
FT1555-BM230
SEAL TIME (SEC)
3.5 2.5
2 1.5 1.25
1 1 0.75 0.75 075
Capsule Application Process
Place correct size CapSeal Capsule on the end of hose or tube fitting. *Reference Size Chart.
Inspect fitting to ensure CapSeal Capsule has shrunk properly.
Place magnetic puck onto the end of fitting. Slowly move fitting through the Air Knife until capsule is completely shrunk.
Pull Tear Strip to remove CapSeal Capsule from fitting.
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
CapSeal Capsule Sizing Chart
CAPSULE SIZES
Inside Diameter x Length in MM
14X24 16X24 18X24 20X23 20X30 22X24 25X27 25X40 28X40 31X33 31X40 34X40 38X40 43X45 46X50 52X60 58X60 67X60 80X60
SIZING
HEX SIZES
COVERED
in mm
10mm to 13mm 12mm to 15mm 14mm to 17mm 15mm to 19mm 15mm to 19mm 18mm to 21mm 18mm to 24mm 18mm to 24mm 22mm to 26mm 24mm to 29mm 24mm to 29mm 27mm to 32mm 30mm to 36mm 32mm to 41mm 34mm to 44mm 41mm to 50mm 49mm to 56mm 55mm to 65mm 64mm to 78mm
HEX SIZES
COVERED
in inches
.39″ to 051″ .47″ to .59″ .55″ to .67″ .59″ to .75″ .59″ to .75″ .71″ to .83″ .71″ to .94″ .71″ to .94″ .87″ to 1.14″ .94″ to 1.4″ .95″ to 1.14″ 1.07″ to 1.26″ 1.19″ to 1.42″ 1.26″ to 1.61″ 1.34″ to 1.73″ 1.62″ to 1.97″ 1.93″ to 2.20″ 2.16″ to 2.56″ 2.52″ to 3.07″
STRAIGHT ELBOW
*FITTING
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Capsule Size Selection by Fitting
Specifications
Item Machine Dimensions (w x d x h) FT1555-BM230 Weight (net) FT1555-BM230 Voltage Max Power consumption Current Set Temperature Heat Gun FT1555-BM230 Exterior temperature housing FT1555-BM230 Duty Cycle Noise Emission Heating element life Electrical Connection Requirement
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Specification 254 x 584.2 x 279.4 mm
9.57 Kg / 21.1 lbs
230-240 VAC 50/60 Hz 3400W 14.78 Amps 330 °C / 631 °F
60-80 °C / 140-175 °F
100% <65 dB(A) Approx. 500-800 hrs. 230-240V, 15 Amp, Grounded L6-15 NEMA twist lock
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Wiring Diagram 230V-AK
Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
FT1555-BM230 Exploded View
4
9
1
4
B
3
10 11 5
8 6
2
1
Item 1 2 3 4 5 6 7 8 9 10 11
12
13 14 15 16
Description
Part Number
Quantity
2.0″ Air Knife
UC2.0-AK
1
Hot End Plate
UC-HS-G3-HEP
1
Base
UC-HS-G3-BASE
1
Cover
UC-HS-G3-COVER
1
divider
UC-HS-G3 DP
1
Heat Gun
UC-HG5000E
1
Cradle
UC-HS-G3-Cradle
1
Cold End Plate UC-HS-G3-CEP
1
Mag Plate
UC-HS-G3-MP
1
Buffer Plate Rocker Switch
UC-HS-G3-BP UC-HS-SWITCH
1 1
B
Fan Guard and Filter
UC-19155k22
1
Rubber Feet
UC-2572k25
1
Cord Grip
UC-MCG50A450
1
CORD
UC-70615NP
1
insulation
UC-9328k41
1
2 3
13
A
4
12
7
14
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF <INSERT COMPANY NAME HERE>. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF <INSERT COMPANY NAME HERE> IS PROHIBITED.
NEXT ASSY
USED ON
APPLICATION
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL
INTERPRET GEOMETRIC TOLERANCING PER:
MATERIAL
DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS:
FINISH
DO NOT SCALE DRAWING
A
NAME
DATE
JTC 8/11/22
TITELEx: ploded View of the
230V Clean Seal
System
SIZE DWG. NO.
REV
UC-CBSS-230V-AK exploded view
SCALE: 1:10 WEIGHT:
SHEET 1 OF 1
3
2
1
Machine Plate
The Machine plate is located on the back side of the machine, left of the power cord.
FT1555-HH-AK20 Exploded View
4
B
2 3 4
3
1 1
5
2
1
Item
Description
Part Number
quantity
1
Heat Guard Assemnly
UC-HS-G3-HGA
2
2
Air Knife Back
UC-HS-AKB
1
3
Air Knife Adapter UC-HS-G3-240ADP
1
4
Air Knife Front
UC-HS-AKF
1
5
Ceramic Spacers UC-HS-G3-SPACER
8
6
Heat Absorbant Gasket
UC-HS-G3-GSK
8
7
Ultra Low Profile 1/4-20 X 1-1/4 Low
SHCS
Profile SHCS
8
8
locking screw UC-1/4-20X1SHCS
1
B
9
locking nut
UC-1/4-20nut
1
10
6
7
A 4
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF <INSERT COMPANY NAME HERE>. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF <INSERT COMPANY NAME HERE> IS PROHIBITED.
NEXT ASSY
USED ON
APPLICATION
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL
INTERPRET GEOMETRIC TOLERANCING PER:
MATERIAL
DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS:
FINISH
DO NOT SCALE DRAWING
A
NAME
DATE
JTC 8/11/22
TITLE:
Exploded View
2.0 Air Knife
SIZE DWG. NO.
REV
B UC2.0-AK
SCALE: 1:5 WEIGHT:
SHEET 1 OF 1
3
2
1
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Maintenance
!
Disconnect all incoming electrical power to the FT1555-BM230 before you start cleaning or maintaining the system. When
the cleaning or maintenance is complete, you may restore the power
supply.
Air Filter maintenance
Required tools: 5/64 or 2mm Allen wrench, coarse brush or vacuum cleaner with brush. This maintenance procedure can be executed by the operator of the machine.
The scheduled cleaning of CapSeal System Air Filters is
! vitally important to the correct temperature and function
of the heating element and shrinking process. Without proper air flow through the system, the heating element can overheat which will cause internal damage and overheating of the CapSeal Capsule. The amount of airborne contaminants varies from location to location. Daily cleaning of the filter and air intake grill is required when the machine is in use. If you have any questions or concerns about the cleaning procedures or correct operation of the unit, please contact us immediately at fpgproductsupport@ danfoss.com or your supplier outside the USA.
1. Turn off the power switch. Disconnect the FT1555-BM230 from the power source and remove the unit from service.
2. Visually inspect the system for signs of overheating. Examples of overheating may include discoloration of the stainless-steel cover, cracked or peeling warning labels, or deformation of the rubber foot mounts.
3. Remove the black plastic filter retainer on the end plate and remove the foam filter. Wash the foam filter in warm water with soap and dry completely.
4. Remove the 4 screws that hold the filter base in place, using a 2mm or 5/64″ Allen Wrench (not included)
5. Use a coarse brush (not included) for removing any debris from the heating elements’ air intake grill that could obstruct air flow. A vacuum cleaner with brush attachment is also acceptable for cleaning.
6. Reinstall the foam filter and retainer.
7. Return the FT1555-BM230 to service (see page 4)
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Troubleshooting
Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual
Problem Capsule does not fit properly Capsule doesn’t shrink Capsules melt during shrinking process
Unit doesn’t blow air
Cause Wrong diameter capsule for application
Machine is turned off/ Not heated to max temp. Temperature is too high. Holding capsule in the AK for more than 5 seconds
Faulty electrical Overheating
Solution
Measure outside diameter of the fitting and use advised capsule.
Turn on machine as described in section 2.4 Reference Time chart on page 7
Check foam filter and air inlet of the Heat gun. Clean both filters as described under 3.1. Check temperature settings. Display on heat gun should read as follows: FT1555-BM230 325-330ºC
Check breaker and power supply. Check filters and clean as described under 3.1
Repairs
All electrical components comply with the relevant safety regulations. Repairs to the electrical components should only be performed by a qualified electrician. Otherwise, the user may run the risk of accidents.
Advised Spare parts
Part Number Item
UC-HG5000E UC-1955K22 UC-2572K25 FT1555-SMP FT1555-LMP
Description
HG5000E 230V Heat Gun CSS- Plastic Fan Guard with Filter Insert CapSeal System Bumper Feet Small Puck Large Puck
Exploded view #
230V-AK
2.0 AK
6
12
13
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Danfoss FT1555-BM230 Bench Mount Hose Capping System Operator’s Manual CapSeal Capsule Sizing Chart
Modifications
Disposal
!
Do not attempt to make any modifications or alterations to the machine without the prior express agreement of
Danfoss. Unauthorized modifications or alterations to the machine
could lead to serious personal injury.
Electrical and electronic equipment, accessories and packaging must be recycled in an environmentally compatible manner. Ensure compliance with local legislation, regulations, instructions and precautions concerning health, safety and environment.
Please call Danfoss with any questions regarding the safe operation of the FT1555-BM230.
RoHS
All surface treatments and materials contained in the manufacturer’s products do not contain any of the prohibited substances specified in Directive 2011/65/EU.
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About Danfoss Power Solutions FC
Danfoss hoses, fittings, and tooling provide the ultimate fluid conveyance solutions for a variety of equipment and applications around the world. We proudly engineer to support a sustainable future for tomorrow.
To learn more please visit: http://www.danfoss.com/en/about-danfoss/our-businesses/ power-solutions
Danfoss Power Solutions 14615 Lone Oak Road Eden Prairie, MN 55344, USA Phone: 952-937-9800
Danfoss Power Solutions (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515-239-6000
Danfoss Power Solutions GmbH & Co.OHG Krokamp 35 D-2439 Neumünster, Germany Phone: +49 4321 871 0
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Danfoss Power Solutions Trade (Shanghai) Co. Ltd. Building #22, No 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 3418 5200w
Danfoss can accept no responsibility for possible errors in catalogs, brochures, and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent
changes being necessary in specifications already agreed. All trademarks in this material are the property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
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