MANUAL TUBEFORMER - 1602 - 2012 - 08 - 22 - en

SPIRO SA
Tubeformer 1602
Date: 22.08.2012 Instruction Manual
Instruction Manual
SPIRO tubeformer 1602
Machine NumBer: __________
Warning: To reduce the risk of severe personal injury do not operate this unit unless you have thoroughly read
and understood all warnings and instructions contained in this manual and have received proper instructions and
training from qualified personal.
SPIRO INTERNATIONAL
INDUSTRIESTRASSE 173
3178 BÖSINGEN
SWITZERLAND
INFO @ SPIRO.CH
WWW.SPIRO.CH
RECEPTION +41 31 740 31 00

SERVICE DEP. +41 31 740 31 99
SALES DEP. +41 31 740 31 00
SPARE PARTS +41 31 740 31 06
+41 31 740 31 96
SPIRO SA Tubeformer 1602
Contents
0.0 GENERAL FUNCTION DESCRIPTION AND DATA 5
1.0 SAFETY INSTRUCTION AND INSTALLATION 5

1.1 SAFETY INSTRUCTIONS AND WARNINGS 5
1.2 LAY OUT 7
1.2.1 Lay out 1602 with horizontal decoiler and slitter 7
1.2.2 Lay out 1602 with vertical decoiler and slitter 8
1.3 INSTALLATION 9
1.3.1 Electrical requirements 9
1.3.2 RUN‑OFF TABLE ASSEMBLY 10
1.3.3 Decoiler 11
1.3.4 Aligning the main unit and run-off table 11
2.0 PRODUCTION SETUP AND ADJUSTMENT 12

2.1 TUBE FORMING COMPONENTS 12
2.1.1 FORM ROLL UNIT - STRIP DIMENSIONS TABLE 12
2.1.2 GUIDE ROLLER ADJUSTMENT 13
2.1.3 CLINCHING ROLLER 14
2.1.4 FOLDING FINGER 15
2.1.5 FLANGE ROLLER 16
2.1.6 SUPPORT ROLLER 17
2.1.7 ROLLER HOUSING 18
2.1.8 DRIVE ROLLERS - HYDRAULIC PRESSURE TABLE 18
2.1.9 GUIDE PLATES 19
2.1.10 FORMING HEAD 20
2.2 STARTING UP 21
2.2.1 ENTERING THE STRIP MATERIAL 21
2.2.2 CHANGE OF DIAMETER 22
2.3 STRIP MATERIAL QUALITIES 23
2.3.1 STEELS AND ALLOYS 23
2.3.2 PLASTIC-COATED STEEL 26
2.3.3 SURFACE PREPARATION 26
3.0 PRODUCTION CONTROL SYSTEM STD. 27

3.1 CONTROL PANEL 27
3.2 DESCRIPTION OF CONTROL PANEL 28
3.3 PROGRAMMING THE DISPLAY. 30
3.4 MAIN MENU 31
3.5 TESTRUN 31
3.6 MACHINE PARAMETER 31
3.7 SETUP 31
3.8 PARAMETER 32
3.9 CORRUGATION PARAMETER 32
3.10 TUBE LENGTH CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM) 33
3.11 MANUAL CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM) 33
3.12 AUTOMATIC CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM) 33
3.13 MODE SET 33
G:\MANUAL\INSTRUCTION_MANUAL\TUBEFORMER1602_2007_03_26 .PMD
3.14 MODE MAN 34

3.15 MODE AUTO 34
4.0 MAINTENANCE AND TROUBLESHOOTING 35

4.1 TROUBLESHOOTING 35
4.1.1 THE TUBE IS NOT RIGID 35
4.1.2 THE LOCKSEAM IS NOT SUFFICIENTLY COMPRESSED. 35
4.1.3 THE LOCKSEAM IS NOT CORRECTLY FILLED. 35
4.1.4 THE FOLDING FINGER DOES NOT WORK SATISFACTORILY. 36
4.1.5 MAKE SURE THAT THE CORRECT CLINCHING ROLLER IS USED. 36
4.1.6 THE STRIP OR TUBE BUCKLES IN THE FORMING HEAD 36
4.1.7 THE STRIP FLANGE AND CHANNEL DO NOT PROPERLY INTERLOCK. 37
4.1.8 BUCKLES BETWEEN THE FORM ROLL UNIT AND THE DRIVE ROLLERS. 37
4.2 MAINTENANCE 38
4.2.1 PNEUMATIC & PRESSURE RISER HYDRAULIC SYSTEM OVERVIEW 38
4.2.2 PNEUMATIC/HYDRAULIC DIAGRAM 070649 39
4.2.3 RECOMMENDED LUBRICANTS 40
4.2.4 MAINTENANCE SCHEDULE 41
5.0 HOW TO ORDER SPARE PARTS 42
6.0 layout 43
7.0 hydraulic dIAGRAM 44
0.0 GENERAL FUNCTION DESCRIPTION AND DATA
Diameter range: 80 to 1600 mm

Can on request be delivered in gauges from 3” to 64”.
Thickness range: 0.4 to 1.3mm galvanized steel, stainless steel up to 0.8mm, and
aluminum up to 1.3mm all in lock former quality.
Strip with: Standard 137mm until 1mm thickness, 140mm above.

Other sizes on request.
Decoiler: Vertical DCV-1000 for one coil up to 1000 kg (see separate brochure).
Corrugations: Either one or two beads.
Lock seam: Outside tube, on the inside on request.
Production speed: max. 80 meters/min. depending on material.
Sound pressure: A-weighted sound pressure level at workstation 78 dbA
Tube cutting: the patented flying slitter.

Saw only on request.
1.0 SAFETY INSTRUCTION AND INSTALLATION

1.1 SAFETY INSTRUCTIONS AND WARNINGS
To reduce the risk of severe personal and fatal injury the following warnings, as well as all other instructions and warnings
contained in this manual, must be read, understood and followed:
Warning
• Never operate the machine until you have thoroughly read and understood all instructions and warnings contained
in this manual and have received proper instructions and training
• Never operate the machine without heavy duty, non slip gloves. The sharp edges of the strip and the sharp ends of
the finished tubes can severely injure fingers and hands.
• Never operate the machine without proper eye protection. During the tube forming and cutting process, especially
when using a saw, pieces of metal or other particulate matter can strike your eyes. Non – fogging , vented safety
goggels or a face screen is recommended. Theire use reduces the risk of eye injuries.
• Never operate a saw or grinder in the vicinity of flammable material, in a volatile environment or while wearing
polyester or other potentially flammable work cloths. While cutting the saw blade creates hot sparks which can
cause fire and or severe personel injury. If work cloths become contaminated with gasoline or other volatile
substances, immediately shut off the equipment and change cloths.
• Never operate a saw or grinder without proper ear protection.
• Never touch any rotating or moving parts while the machine is running. Severe personal injury can result. Never
operate the machine unless all covers and access panels or doors are closed.
• Never perform any service work unless the main power supply has been disconnected.
• Never remove the cover of the electric box unless the main power supply has been disconnected. Hazardous
voltage can result in death or severe personal injury.
• Never run the machine unattended.
• Check the functions of safety and emergency switch daily.
• Never modify the machine in any way . Only parts supplied by Spiro or expressly approved by Spiro for use on
its equipment are authorized. Although certain unauthorised parts may be useable with Spiro equipment, their use
may be extremely dangerous.
• Never remove any guard or safety devices.
• Never operate the machine while you are fatigue or under the influence of any substance, including drugs and
alcohol, which might impair vision, dexterity or judgment.
• Never operate the angle adjusting switch if anybody is in touch with the machine.
• Always wear proper clothing when operating the machine. Clothing must be heavy duty, non-flammable and
snug fitting but allow complete freedom of movement.
• Never wear loose fitting clothing or jewelry that could become entangled in the equipment. Heavy duty non slip
gloves and boots, a face shield or safety goggels and ear plugs when using a saw or grinder are a must to protect
your hearing. Wear an approved safety hard hat to protect your head.
• Never attempt to process materials other than specificially authorized in this manual.
• Processing other types and sizes of material can damage the equipment and can result in severe personal injury to
the operator or third parties.
• Never operate the machine within 5 meters (15ft ) of bystanders. Sparks, fragments of metal or other particular
matter can cause fire and/or severe personal injury.
• Always have mechanical or electrical service done by trained and qualified personnel.
• Saw blade: If the unit is equipped with a recessed, automatic saw blade that rises from inside of the saw blade
housing when activated by remote limit switch never place hands or other body part in or on the saw housing
while the electric power is on or while the machine is in operation.
• Contact with a moving saw blade will cause severe or fatal personal injury. Even contact with a stopped saw
blade or one rotating slowly can cause severe personal injury. Do not touch the saw blade and do not operate this
unit unless the saw blade housing is properly and securely in place.
• Check the saw blade of cracks. Use only Spiro genuine blades.
• The saw blade may continue to rotate for several seconds after it is deactivated and after it withdraws into the
housing. Never put hands or fingers on or into the housing.
• With the mainpower supply disconnected, examine the saw blade for any signs of excessive waer or damages at
regular intervals. Do not use damaged or worn saw blades.
• Never repair a damaged saw blade . It could end in serious or fatal personal injury.
Pay also attention to the safety rules conc. internal transport and the possible local safety rules.
1.2 LAY OUT
1.2.1 Lay out 1602 with horizontal decoiler and slitter
1.2.2 Lay out 1602 with vertical decoiler and slitter
R=2600
1.3 INSTALLATION
With most new installations, a technical representative from Spiro will supervise the installation and initial setup and
adjustment of the machine. A complete installation will consist of the main tube-forming unit with the addition of different
types of decoilers, cutters and run-off tables. The electrical requirement table below gives an indication to the different
types of installations. Please refer to the appendix for any documentation specific to your installation.
SLITTER
CONTROL PANEL
ELECTRICAL
CABINET
LUBRICATION
PUMP MOTOR
1.3.1 Electrical requirements
The table below indicates the total power consumption for the main unit with cutter.
Mainmotor Total power con- Maximum

MACHINE TYPE: Voltage Fuse
kW sumption KVA cable
1602 380-480 15 32 63A 35mm2
1602 200-240 15 26 80A 35mm2
DCH 3000 380-480 7.5 11 16A 10mm2
DCH 3000 200-240 7.5 10 25 A 10mm2
DCV 1000 0 0 0 0 0
1.3.2 RUN‑OFF TABLE ASSEMBLY
Each run‑off table have two end‑frames (1), which have bearings for the two adjustable cylindrical supporting rolls (2).
Cogwheel segments (3) keep the support rolls in equal distance from the centreline, and the adjustments of the distance
between the two rolls (which has to be done for every change in tube diameter), are effected by means of the handle (4),
located on the second end-frame. The support rolls are mounted in both of the two end‑frames, which are bolted together by
means of 4-distance bars (5). The two upper bars have taps (6) for connecting the receiving ramp (7).
When assembling the run‑off table, put first the support rolls into their bearings in each of the end‑frames. Then fit the four
frame bars and screw it together. Check that the cog‑segments are putted into correct mesh, so that both support rolls have
the same distance from the centreline of the table.
On each table there are two discharge arms (12), which lift the tubes up from the support rolls when the cutting operation is
finished. The discharge Arms are linked together with a parallel rod (13), and between the first and second table these rods
are connected by a coupling. When connecting the rods, be sure that the angle of the discharge arms are Identical at the first
and second table.
To adjust the height of the tables, each end‑frame is placed on floor plates (15), which later on when the machine is lined
up, are fastened to the floor by expansion bolts. The end‑frames are fastened to the floor plates by bolt (17), which also are
height adjustment screws. When the height of the table later on is determined, these bolts are fastened by tighten the nuts
(18) and those are keeping the tables in position in all directions.
The first end‑frame of table no 1 is equipped with a pneumatic cylinder (19) for engaging the discharge arms. Two air-hoses
from the machine have to be connected to the cylinder when assembly work with the run off table is finished.
7 2
8 3 9
13
4
12
6
5
19
1
17
1
18
15
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1.3.3 Decoiler
There are two main types of decoiler: horizontal and vertical. The decoiler will maintain an assisted feed of the strip mate-
rial to the main unit. The installation drawings will indicate the space requirements and safety zone for the decoiler specific
to your installation. Page 7-8
1.3.4 Aligning the main unit and run-off table
Line the machine up according to the installation drawings. The main unit and decoiler must be fastened to the floor with
expansion bolts before the upstart. The main unit should be leveled up carefully, with the machined surface on top of the
leveling bed. If the machine should fall out of level, the alignment of the run-off table and the flow of lubricant oil could be
affected.
Movable remote controls

Forming head
Adjustable support rollers
Control
panel Must be
Slitter in level
Electrical
Hydr.discharge cylinder cabinet
Expansion
Height adjustment bolts Lubrication bolts
pumo motor
The run-off table must be lined up with a. 200-250 mm diameter tube in the machine. Run a short length of tube until the
tube just touch the leading edge of the adjustable support rollers. Adjust the height of the table by means of the bolts, and
allow the tube to touch the support rollers slightly without bending in any direction. Then proceed with another 1-meter
tube length. For every 1-meter of tube, adjust the remaining part of the run-off table, until the whole unit is in line and
level with the produced tube. The centerline of the produced tube (a) must at all times be in level with the tube former unit.
Height adjustment:
The distance between the top off the end frame run off
table and the lower side of the tube has to be approximately
130mm.
The length control photocell (b) is fastened to a tube below

the rollers. It is important to set the distance from the tube
wall to the photocell to be 25-30 mm. The photocell has to
be 90°to the tube wall. This means that the direction of the
photocell has to be to the center of the tube (a).
2.0 PRODUCTION SETUP AND ADJUSTMENT

2.1 TUBE FORMING COMPONENTS
Certain adjustments must be made when the machine is first started and when tube diameters are changed. This chapter
describes the functions and adjustments of the mechanical forming components.
2.1.1 FORM ROLL UNIT - STRIP DIMENSIONS TABLE
Refer to the table and make sure that the correct form roll unit is mounted in the machine. Observe that the strip thickness
includes the maximum tolerance. As an example: 1,25 mm Standard strip thickness for galvanized steel is equivalent to
.0516 inches and should only be ordered with a negative tolerance.
Form roll Strip thickness Strip width

unit
Inches mm US Std. US Std. S.W.G. B.G. Inches mm
Black Steel Galvanized
No. 0 .0150-.0217 0.4-0.6 25-28 26-30 25-28 26-28 3.071 78.0

No. 1 .0150-.0217 0.4-0.6 25-28 26-30 25-28 26-28 5.197 132.0
No. 1A .0150-.0217 0.4-0.6 25-28 26-30 25-28 26-28 5.394 137.0
No. 2 .0218-.0320 0.6-0.8 22-24 23-25 21-24 22-25 5.394 137.0
No. 3 .0321-.0400 0.8-1.0 20-21 20-22 19-20 20-21 5.394 137.0
No. 4 .0401-.0516 1.0-1.3 18-19 18-19 18 18-19 5.500 140.0
The form roll unit consists of 3 sets of form rollers. The guide
rollers (e) also serve as a lubricating station (a).
The end roller (c) are inter-changeable. It is possible to adjust the

A guide rollers sideways in order to obtain correct folding of the
B flange and of the channel of the strip.
C
The guide rollers are fixed in position by a setscrew (d), and the
D unit is fastened with two bolts (b) through the base of the roller
housing.
E
2.1.2 GUIDE ROLLER ADJUSTMENT
The guide rollers should be adjusted sideways in order to

obtain the correct measurement of flange “A”.
A B
Increase flange “A” to correct (a)
Decrease flange „A“ to correct (b)
Form
Roll Flange A
Unit
MM Inches
No.0 4,7 0,185

No.1A 6,3 0,248
No.2 6,3 0,248
No.3 6,5 0,256
No.4 7,7 0,303
2.1.3 CLINCHING ROLLER
The adjustment of the clinching roller is made manually by turning the screw (D) situated inside of the cabinet.
To change clinching roller, first loosen the set screw (A), B A C

then unscrew the bolt (B) with washer and distance ring.
When the shaft has been unscrewed (C) the clinching
roller with ball bearing can be pressed off the shaft.
The easiest way to exchange the clinching roller is to pull

out the clinching roller together with the fork and the
shaft und clamp the whole unit on a vice.
It is possible to adjust the clinching roller laterally by tur-

Clinchingroller
ning the shaft. The lateral position of the clinching roller
in relation to the lock seam is important in order to obtain Parallel
a perfect lock seam. The center of the seam must be in the
center of the roller-groove.
Lower guide plate
2.1.4 FOLDING FINGER
1
Adjust the distance between the guide plate (2) and the folding
finger (1) until the channel of the strip gets sufficient clearance to
pass through. The purpose of the folding finger is to bend or help
fold the strip channel about 35 degrees. This bending of the chan-
nel is made just prior to the clinching operation of the lock seam.
2
2.1.5 FLANGE ROLLER
The flange roller is mounted in the roller holder in front of the upper guide plate. Turn the handle, causes an eccentric
movement of the roller. The roller must be set in a position that makes the strip flange bend 35 degrees.
3 1.5
A B
The flange rollers come in two sizes.
A: The heavy duty flange roller for strip thickness above 1 mm, for form roll units no. 4.
B: The standard type for strip thickness 0,4 mm to 1 mm, or for form roll units no. 1-2-3.
2.1.6 SUPPORT ROLLER The support roller (1) is mounted on the same holder as the
flange roller. The support arm is fixed in its pressing positi-
a on to press the roller against the strip material, and the arm
handle is pressed firmly down.
In order to prevent the support roller from making a groove

in the strip material/tube, care should be taken not to press
the arm too much,
1 2
a=0-1/2°
The angle of the support roller in relation to the guide plate or the channel of the strip, should be between 0 and 1/2 de-
grees. This will prevent the strip from “jumping out”. The correction of the angle is effected by means of an eccentric
adjusting screw (2) located in the roller holder.
Support roller holders come in two different sizes:
The standard types for strip thickness 0,5 mm to 1 mm or for form roll units no 1-2-3.
The heavy duty flange roller for strip thickness above 1 mm. (Option)
In order to fit the two types of roller holders, there are two different types of B
support arms. One standard arm for the thinner strip thickness (A) and one
heavy duty arm for thicker strip (B) (Option). It is not possible to use the
heavy-duty support roller and heavy-duty arm for tube diameters below 125
A
mm or 5 inches.
2.1.7 ROLLER HOUSING
Set the roller housing to the correct angle for the selected tube diameter. It is important to set the angle before mounting
the forming head in the machine. The angle adjustment should be set against the calibrated scale one the main unit table.
The clinching roller might get damaged if the roller housing is moved to an angle that does not correspond with the for-
ming head.
2.1.8 DRIVE ROLLERS - HYDRAULIC PRESSURE TABLE
The drive rollers consist of two rollers, one upper and one lower drive roller. The upper drive roller has got a knurled sur-
face and serves as the powered drive roller, whereas the lower drive roller has got a smooth surface and works as support
roller. The hydraulic pressure on the drive rollers is adjustable by the drive roller pressure valve. A gauge indicates the
pressure.
STRIP THICKNESS HYDRAULIC PRESSURE KG/cm2

US Std. Gauge
Galv. Stainless Non-ferrous
mm Inches S.W.G. B.G.
Black Steel Galv. Steel Steel Steel (Aluminum)
0.4 0.016 27-28 30-29 27 27-28 15-20 20-25 10-15

0.5 0.020 25-26 27-28 25-26 25 15-25 20-30 10-20
0.6 0.024 24 25 23-24 24-25 15-25 20-30 10-20
0.7 0.028 22-23 24 22 23 20-30 25-35 15-25
0.8 0.032 21 22-23 21 22 20-30 25-35 15-25
0.9 0.036 20 21 20 21 25-35 30-40 20-30
1.0 0.040 -- 20 19 20 30-40 35-45 25-35
1.1 0.044 19 -- -- 19 35-45 30-40
1.25 0.050 18 18+19 18 18 35-50 30-45
2.1.9 GUIDE PLATES
The machine is fitted with 4 standard guide plates, the upper and lower front guide plates and the upper and lower rear
guide plates. An opening between the front and rear plates facilitates cutting of the strip material when the tube diameters
are being changed.
A special set of sheet inlays has to be fixed between the plates. The purpose of the inlays is to allow the strip free passage
between the upper and lower guide plates when the plates are being pressed together by means of the guide plate lock and
support arm. The inlays should always be thicker than the strip material used. Refer to the table for correct tolerance. The
guide plate lock, which is an eccentric locking device, is fitted with two adjustable set screws (2), to accommodate the
different thickness of the sheet inlays (1).
Strip material thickness

Thickness of 28 24 21 19 Gauge (US std)
inlays
0.4-0.6 0.6-0.8 0.7-1.0 1.1-1.3 mm
Form Roller Unit No. 1 No. 2 No. 3 No. 4
Between upper and lower guide plates 0.7 1.0 1.25 1.5 mm
Underneath lower guide plates 1.25 1.0 0,7 0.5 mm
The inlays underneath the lower guide plates make it possible to adjust the strip material tangential to the upper drive roller.
2.1.10 FORMING HEAD
The forming head is located on the base and clamped in position by means of a lock piece. Before fastening the lock piece
with screws, make sure that the clinching roller can be moved freely up and down hydraulically without touching the sides
of the opening in the floor plate of the forming head (3)
2
(1) Bronze lining forming head
(2) Lubricating oil supply
(3) Opening for clinching roller

1
3
3.2 DESCRIPTION OF CONTROL PANEL
SWITCH/SELECTOR
�� FUNCTION
MAIN ON Starts the hydraulic pump.
MAIN OFF Stops all functions.
OPERATE ON Starts the tube production.
CUTTER ON Starts the cutting of the tube.
DISCHARGE ON Operates the discharge function on the run-off table.
OFF Stop the production of the tube.
LUB. OIL Lubricant oil supply „OFF/ON“
MODUS SET Mode for control of each step in the production.
MODUS MAN Mode for production start, calibration, change of diameter etc.
MODUS AUTO 1 Automatic production of one programmed tube length at a time.
MODUS AUTO 2 Automatic production of a programmed series of tubes.
PRODUCTION SPEED Selects the production speed for the tube.
CUTTING SPEED Selects the speed for the tube cutting cycle.
DRIVEROLLER DOWN / UP Pressure on lower drive roller On Off.
CLINCHINGROLLER DOWN / UP Pressure on clinchingroller On Off.
ANGLE UP / DOWN Adjusting of roller housing angle. (Option)
CORRUGATION ON / OFF / AUTO Corrugation unit On Off Auto. (Option)
JOG Fixed slow speed, slitter cover open.
Setting of pipe lengths:
The machine is equipped with 2 no. limit switches on the receiving table. These are located in holders that move along a
track so that the switches can be positioned to suit the required pipe length.
Limit switch A (Fig.2) is located nearest the machine and ensures that the production speed is reduced before the pipe
reaches limit switch B (Fig.2), when the pipe cutting starts.
Limit switch A is usually set approximately 250 mm in front of switch B. This distance may be reduced with the produc-
tion of large diameter pipes.
The positioning of limit switch B determines the length of the pipe.
A B

Fig. 2
3.3 PROGRAMMING THE DISPLAY.
USE OF KEYS ON THE DISPLAY
NUMBER 0-9 Used to type in lenghts, quantity etc.
HOME Jump to main menu (not in use in all menus)
ALARM Shows alarms in the machine
ACK Not in use
<- Back one step when you type in numbers etc.
<-I Enter
ARROWS Move curser in operator panel
CALIB Calibrate the machine in manual mode
SETUP Jump to machine setup (Main off)
PARAM Jump to machine parameter (Main off)
CORR Jump to Automatic corrugation (Option) parameter (Main off)
RESET COUNTER Reset production counter (Auto 1 or Auto 2)

3.4 MAIN MENU
This is the menu you see when the machine is in Main off, from this menu you can reach SETUP, PARAM and CORR.
If you use the arrows to go down in this menu you will find the production info.
Here you can read timers for Main on and production, length for produced tubes and used strip.
You also find a log in, that is used for Testrun and Machine parameter.
Passsword is 1602 for Tubeformer 1602 and 3600 for Tubeformer 3600.
3.5 TESTRUN
In this menu you can force some of the outputs in the machine.
Be carefull because parts in the machine will move when you doing this.
Move the curser to the output you want to force.

Press enter to toggle the output.
3.6 MACHINE PARAMETER
In this menu you set up machine parameters
1. Discharge. Standard or AROT (option)
2. Time Stop-Cut. Time after stop of tube until machine start cutting
3. Distance AROT. Max length of the tube before the AROT must be in start position.
4. Limit. Number of pulses on encoder that we need to stop before we are in correct length of the tube.
5. Limit Flying. Number of pulses on encoder that is left on the tube when the slitter knife start to go up, when
running with “SLITTER FLYING”.
6. Measure scale. This change the scale you type in and the machine shows all lengths in the machine. You can
choose between mm and inch.
3.7 SETUP
Here you find setup for
1. Cutting system
2. Length measure system
3.8 PARAMETER
Here you find parameter for
1. Low speed . Number of pulses on the encoder that is left on the tube when machine goes down to lowspeed to
reach the right length of the tube (only for lenghtmeasure system).
2. Timer delay discharge. The time discharge need to discharge the tube.
3. Timer delay slitter. The time the slitter need to go throw the tube wall.
4. Timer delay saw. The time the saw need to go throw the tube wall.
5. Timer delay plasma. The time the saw need to go throw the tube wall.
6. Calibration position (Slitter, Saw, Plasma) (only for lenghtmeasure system).
3.9 CORRUGATION PARAMETER
Here you find settings for automatic corrugation (option)
1. Corr.Free length start and stop
2. Distans between corrugation unit and cutting unit. (Slitter, Saw, Plasma)
3.10 TUBE LENGTH CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM)
Important : Check that the photocell is clean and adjusted 90 degress relative the to the centreline of the tube. Use a short
length of tube to verify that the distance between the photocell and the tube is appr. 25 to 30 mm.
3.11 MANUAL CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM)
Manual calibration must be carried out after installation and if distance between the photocell an the cutting point is chan-
ged.
This calibration is the basis for all automated calibration.
1. Make a straight cut in SET mode
2. Switch to MAN mode
3. Press CALIB on the operator panel keypad. (panel jumps to calibration menu)
4. Press OPERATE ON. Machine starts to run the tube according to the production speed potentiometer. Machine
will stop when the tube comes to the photocell.
5. Measure the tubelenght from end of the tube to the cutting point (Slitter, Saw, Plasma) and type it in on the
operatorpanel.
6. Press CALIB to return to the MAN mode menu
3.12 AUTOMATIC CALIBRATION (ONLY FOR LENGHTMEASURE SYSTEM)
Automatic calibration must be carried out when the tube diameter or cutting system is changed.
1. Make a straight cut in SET mode
2. Switch to MAN, AUTO 1 or AUTO 2

a. MAN: Program a length 200mm longer than the manually calibration length
b. AUTO 1 or 2: The first length must be 200mm longer than the manually calibration length
3. Press operate on to start produce the tube according to programmed length
3.13 MODE SET
Runs Operate, Cut and discharge in SET mode.
Note that the lenghtmeasuring (lenghtmeasuring system or limit switch system), max length and strip stop signal is not in
use.
3.14 MODE MAN
Length measuring system

Runs Operate, Cut and discharge in MAN mode.
Type in the length you want on the produced tube.
Possible to press CALIB for making a manual calibration.
Limit switch system

Runs Operate, Cut and discharge in MAN mode.
Produce tubes according to the limit switches.
3.15 MODE AUTO
Length measuring system

Runs Operate, Cut and discharge in AUTO mode.
Possible to start machine in AUTO mode by pressing OPERATE ON.
If you want to change length, quantity or series press ENTER (EDIT PROGRAM)
Type in quantity and length, if you put in zero in quantity the serie stop and all quantity and lengths after will be set to
zero.
Auto 1
The machine will run the tube to the programmed length and cut it.
Possible to press DISCHARGE to discharge the tube or press OPERATE to start the next tube.
Auto 2
The machine will run the tube to the programmed length, cut it and discharge.
The machine stops when the programmed serie is produced.
Limit switch system

Runs Operate, Cut and discharge in AUTO mode.
Possible to start machine in AUTO mode by pressing OPERATE ON.
Produce tubes according to the limit switches.

Type in quantity of tubes you want to produce.
Auto 1
The machine will run the tube to the limit switch and cut it.
Possible to press DISCHARGE to discharge the tube or press OPERATE to start the next tube.
Auto 2
The machine will run the tube to the limit switch, cut it and discharge.
The machine stops when the programmed quantity is produced.
4.0 MAINTENANCE AND TROUBLESHOOTING

4.1 TROUBLESHOOTING
4.1.1 THE TUBE IS NOT RIGID
4.1.2 THE LOCKSEAM IS NOT SUFFICIENTLY COMPRESSED.
Use the correct clinching roller pressure. Refer to the hydraulic pressure table.
4.1.3 THE LOCKSEAM IS NOT CORRECTLY FILLED.
The flange and channel must have the correct

dimensions resulting from the form rolling process.
Adjust the strip sideways by means of the guide
rollers.
Increase flange «A» to correct for (a).
Decrease flange «A» to correct for (b).
Even when the dimensions of the channel and flan-

ge are correct there might be a tendency, especially
when forming thin-walled tubes, that the tube is still
cracking when lifted.
When forming tubes from 0.4mm strip, the flange and channel tend to have a slight radius at the flange and channel.
In such cases the flange roller should be pressed a little harder against the
strip flange, thereby improving the profile. The pressing of the flange roller
will also lengthen the flange a little and the lock seam will be correctly
filled. Always check that the correct flange roller for the strip thickness is
used!
4.1.4 THE FOLDING FINGER DOES NOT WORK SATISFACTORILY.
Check the finger pressure against the strip channel and check that the finger is really folding. The tip of the finger might be
broken or worn out, and needs replacement.
4.1.5 MAKE SURE THAT THE CORRECT CLINCHING ROLLER IS USED.
The depth of the groove in the clinching roller must never be deeper than the height of the lock seam (strip thickness x 3).
The machine is supplied with two different clinching rollers. No. 1 is for strip thickness 0.4 - 0.6 mm (26 - 30 gauges), and
No. 2 is for strip thickness above 0.7 mm, or heavier than 24 gauge.
It is possible to order special clinching rollers for all material thickness. (Option)
The position of the clinching roller is also important. The center of the groove normally is in the center of the lock seam.
See section 2.1.3 for adjusting the roller laterally.
4.1.6 THE STRIP OR TUBE BUCKLES IN THE FORMING HEAD
The drive roller is pressing too hard against the strip.
Adjust the oil pressure as specified in the hydraulic pressure table.
If the buckles still appear with the specified oil pressure, the reason might be that the drive roller is not straight across the
surface. Only part of the drive roller is pressing against the strip and thus causing uneven pressure resulting in a rolling of
the strip. The drive roller will in such cases not be suitable for thin-walled tubes, and ought to be exchanged for a new and
straight roller.
Buckles might also occur when the roller housing is not set to
the correct angle. The buckles appear close to the lock seam on
the same side of the strip as the angle is incorrectly set.
If the angle of the roller housing is set to a point which is slightly

too much to the left of the correct angle, the buckles will appear
on the left side of the strip, and vice versa.
4.1.7 THE STRIP FLANGE AND CHANNEL DO NOT PROPERLY INTERLOCK.
When the angle of the roller housing is set, it happens that the seam does not interlock correctly. The strip flange «jumps
out» of the channel, or, a climbing action of the flange takes place on the left side of the strip channel. This is due to incor-
rect mounting of the support roller holder on the guide plate. Adjust the angle of the support roller to the specified neutral to
1/2 degrees.
4.1.8 BUCKLES BETWEEN THE FORM ROLL UNIT AND THE DRIVE ROLLERS.
When the angles of both the support roller and the roller housing have been incorrectly set, buckles might even occur
BETWEEN the form roll unit and the drive rollers (a). These buckles will disappear after correcting the angles as described
above.
When running thin-walled tubes it is very important that the run-off table is set correctly to the produced tbe diameter.
The supporting rolls must not bend the tube in any direction, otherwise «jump out» or «climbing» effects will result. These
failures always occur after running 2 - 3 meters of tube. The beginning of the tube is always trouble free, but after touching
the supporting rolls of the run-off table, the tube gets bent out of its normal direction.
4.2 MAINTENANCE
4.2.1 PNEUMATIC & PRESSURE RISER HYDRAULIC SYSTEM OVERVIEW
Air pressure/quality:
The working air pressure is minimum 6 bar and maximum 10 bar.

Air supply must contain air of good industry quality.
Air filter:
Change air filter (40MY) on filter regulator (pos. No.2) every 6mnd.
Hydraulic system:
The hydraulic system on a standard machine consists of one, separate closed oil circuit.
This system consists of part No. 7,8,10 & 15 on the pneumatic/hydraulic diagram.
Normal oil pressure for the drive rollers is from 10 to 80 bar, depending on the thickness and type of the strip material
used.
Oil volume:
Pressure riser-M733/100: 0.10 L

Oil reservoir -M55903 : 0.25 L
The oil should be renewed when oil seems polluted (see change in color on oil level indicator). At the same time clean
hydraulic parts thoroughly.
Oil level:
Check once every week on level indicator, if any leakage, check all hydraulic fittings.
Oil service:
4.2.2 PNEUMATIC/HYDRAULIC DIAGRAM 070649
40
Texaco Gras
4.2.3
SUBSYSTEM Mobile Shell Total Chevron Castrol Arrow Statoil Esso
Caltex Filium
Real Oil Tellus Azolla OC Turbine Hyspin Hydrap Hydraway Nuto

Hydraulic DTE Light
R & O 32 37 20 Oil 9 AWS 32 46V HMA 32 HP 32
Real Oil Tellus Azolla OC Turbine Hyspin Hydrap Hydraway Nuto

Cutter gear DTE Light
R & O 32 37 20 Oil 9 AWS 32 46V HMA 32 HP 32
Mobilube Meropa Omala Alpha Loadway Spartan

Gear box GX80 68 68 SP 220 EP 220 EP 68
SPIRO SA
Mobilube Multifak Alvania Dura Lith Uniway Beacon

Ball bearings B/B APS 2
Grease EP2 EP2 EP2 Grease EP2 LI 62 EP2
RECOMMENDED LUBRICANTS
Date: 22.08.2012
Scilia AS GB Oil 19C
Forming head Filium

Galvanized steel Mobilmet Soluble Oil Dromus Lactuta Soluble Syntilo Syncut Cool way Cutwell
102
170 C Oil BS LT Oil T R . G 40
(101)
Water soluble SPIROLUBE (Avialable through your SPIRO representative)
Mobilmet Transultex Metalina Sterromar

GB Oil 32
Forming head 427 A GL 220
Stainless steel
Tubeformer 1602
Scotch tape 5421 and water soluble oil

Instruction Manual
Forming head Way Lubri-

Scilia AS
Aluminium cant 68
4.2.4 MAINTENANCE SCHEDULE
System Daily Weekly Monthly 6 months Yearly
Form Roll unit Roller cleaning Clean oil reservoir
Grease spindle and

Angle adj. screw guide tappet
Clean groove with

Clinching roller Check and clean steel brush if neces-
sary
Forming heads Check before use!

Scrape/polish inside
Bronze inlay if necessary
Inside cleaning
Grease support
Guide plates Check when chang-
roller
ing diameter
Drive Check gear oil Change gear oil

system level latest 5000 hours
Clean tank and

Strip lubrication Check lubricant level Check nozzle
filter
6.0 layout
R=2600
7.0 hydraulic dIAGRAM 071304

MANUAL TUBEFORMER - 1602 - 2012 - 08 - 22 - en

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MANUAL TUBEFORMER - 1602 - 2012 - 08 - 22 - en

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SPIRO SA

Date: 22.08.2012 Instruction Manual

Machine NumBer: __________

RECEPTION +41 31 740 31 00

Date: 22.08.2012 Instruction Manual

1.0 SAFETY INSTRUCTION AND INSTALLATION 5

2.0 PRODUCTION SETUP AND ADJUSTMENT 12

3.0 PRODUCTION CONTROL SYSTEM STD. 27

Date: 22.08.2012 Instruction Manual

3.14 MODE MAN 34

4.0 MAINTENANCE AND TROUBLESHOOTING 35

5.0 HOW TO ORDER SPARE PARTS 42

7.0 hydraulic dIAGRAM 44

Date: 22.08.2012 Instruction Manual

0.0 GENERAL FUNCTION DESCRIPTION AND DATA

Diameter range: 80 to 1600 mm

Strip with: Standard 137mm until 1mm thickness, 140mm above.

Corrugations: Either one or two beads.

Lock seam: Outside tube, on the inside on request.

Production speed: max. 80 meters/min. depending on material.

Sound pressure: A-weighted sound pressure level at workstation 78 dbA

Tube cutting: the patented flying slitter.

1.0 SAFETY INSTRUCTION AND INSTALLATION

Date: 22.08.2012 Instruction Manual

Date: 22.08.2012 Instruction Manual

1.2 LAY OUT

1.2.1 Lay out 1602 with horizontal decoiler and slitter

Date: 22.08.2012 Instruction Manual

1.2.2 Lay out 1602 with vertical decoiler and slitter

Date: 22.08.2012 Instruction Manual

1.3.1 Electrical requirements

Mainmotor Total power con- Maximum

Date: 22.08.2012 Instruction Manual

1.3.2 RUN‑OFF TABLE ASSEMBLY

Date: 22.08.2012 Instruction Manual

1.3.4 Aligning the main unit and run-off table

Movable remote controls

The length control photocell (b) is fastened to a tube below

Date: 22.08.2012 Instruction Manual

2.0 PRODUCTION SETUP AND ADJUSTMENT

2.1.1 FORM ROLL UNIT - STRIP DIMENSIONS TABLE

Form roll Strip thickness Strip width

No. 0 .0150-.0217 0.4-0.6 25-28 26-30 25-28 26-28 3.071 78.0

The end roller (c) are inter-changeable. It is possible to adjust the

Date: 22.08.2012 Instruction Manual

2.1.2 GUIDE ROLLER ADJUSTMENT

The guide rollers should be adjusted sideways in order to

No.0 4,7 0,185

Date: 22.08.2012 Instruction Manual

2.1.3 CLINCHING ROLLER

To change clinching roller, first loosen the set screw (A), B A C

The easiest way to exchange the clinching roller is to pull

It is possible to adjust the clinching roller laterally by tur-

Lower guide plate

Date: 22.08.2012 Instruction Manual

2.1.4 FOLDING FINGER

Date: 22.08.2012 Instruction Manual

2.1.5 FLANGE ROLLER

The flange rollers come in two sizes.

Date: 22.08.2012 Instruction Manual

In order to prevent the support roller from making a groove

Support roller holders come in two different sizes:

Date: 22.08.2012 Instruction Manual