DDGJ-1.

2-1500-LY

SPIRAL DUCT MACHINE

OPERATION MANUAL

Dezhou Dadong Machinery Co.,Ltd

Address：Houwei,xinhua office,Dezhou,Shandong,China
TEL.：0534-2728298
Fax.：0534-8925439
Website：www.dzddjx.com E-mail：[email protected]
 CONTENTS

1. Summarization......................................................................................................... 2

2. Technical Datas ........................................................................................................ 2

3. Equipment Components ......................................................................................... 3

⑴ Decoiler ............................................................................................................. 3

⑵ Host machine..................................................................................................... 3

⑶ Introductions of operation panel ....................................................................... 3

⑷ Pressure control panel..................................................................................... 5

⑸ Run-out table ..................................................................................................... 6

4. Preparatory works................................................................................................... 6

5. Operation steps:....................................................................................................... 7

6. Installation and Maintenance Manual.............................................................. 9

7. FAQ and Solution in operation .......................................................................... 10

APPENDIX: ............................................................................................................... 11

1.Electrical elements list........................................................................................ 11

2.Hydraulic System Drawing ................................................................................ 11

3. Air-powered system........................................................................................... 12

4.Electric diagram............................................................................................. 12

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1. Summarization
Welcome to use DDGJ-1.2-1300 spiral duct forming machine,which adopts the decoiler
and main body of integrated design.This machine makes ducts with molds,which can make
the diameters of ducts very accurate.
Features: frequency control of motor speed, PLC control,touchscreen display, roller
shear cutting, cut-to-length with auto measure system, turn over ducts automatically after
cutting.
The equipment is made up of decoiler、host machine、run-out tables.
Operator should read this manual carefully in order to get rid of faults and have a long
machine life.

2. Technical Datas

Diameter range : 100-1500mm

galvanized sheet:0.5-1.2mm，width:137mm
Material:
stainless steel:0.4-0.8mm

Decoiler: vertical, max load 1200kg

Seam lock : located outside the ducts

Feeding speed: 0-27m/min,adjustable

Cutting and turning over ducts adopt air-power;
Drive System
Compaction of feed rolls adopts hydraulic power

cutter: roller shear

Forming head mould: Steel

Total weight: 2000kg

Main machine:3.4x1.8x1.8 mm
Outside size:
Run-out table:2x1.0x1.1m

12KW,main motor 11kw,hydraulic motor 0.75kw,

Total power :
Seam lock wheel 0.12kw.

Electrical source: 380v/50hz/3ph

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3. Equipment Components
⑴ Decoiler
The decoiler is for supporting the material.The coil inside diameter is 460-520mm,
the max coil outside diameter is 1100mm,and max coil weight is 1200kg.The decoiler
is installed on the dump rail and is drived by a small motor to adjust the materials’

feeding angles according to different moulds.

⑵ Host machine
① Forming rolls: shape the steel strip, the feeding roll can be adjusted to left and
right,for adjusting the flanging’s size.

② Feed rolls: clamp the strip and transfer it. Under the rolls,there are two oil
cyclinders, its pressure can be regulated by the electric contact gauges.

③ Guide plate: fix and guide the steel strip.there are one flanging wheel in the guide
plate.

④ Winding tube unit: moulds,seam locking wheel etc.

⑤ Cutting system: roller shear, the slitter is drived by air cyclinder, and the lifting
height is adjustable.

⑥ Control system: hydraulic system and electrical system

⑶ Introductions of operation panel

Touch “ENTER” button, enter into the following interface M2.

3
 M2
Running speed----production speed in automatic working
Cutting speed-----production speed in inching mode and cutting

Press “Setting Menu” button,enter into following interface M3:

M3
Turn Time: 3s Cutter Up: 2s
Interval: it’s useless to roller shear,it’s useful to plasma cutting.
Running hrdraulic Time: 5s,after 5 seconds,the hydraulic pump stops.

4
 M4
“Left” and “Right”--control the decoiler to slide along the dump rail.
“Running Hydraulic ”-- control the hydraulic system,and it’s on when producing the
ducts.
“Cooling” -- control the flow of lubricant,which is used to cool and lubricate the
ducts.
“Manual/Auto”—change two operation ways,when this switch is turnned to middle
position,machine has no action.
“Inching” -- holding on the button, begins to wind duct,release it, stop.
“Cut” -- controls the cutter to raise.
“E-Stop”— stops all the work.

“counter”-- count the quantity of cut ducts.

⑷ Pressure control panel

“pressure regulating of feed rolls”–--It’s electric contact gauges.In the gauges,

which can show and control the pressure of feed rolls.The red pointer indicates the
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max pressure,the green pointer indicates the min pressure. The difference value
between upper pressure limit and lower limit is not more than 1MPa.
If the strip is 0.5mm thick,the pressure is about 5Mpa, If the strip is 1.0mm
thick,the pressure is about 8Mpa.
You can adjust the pressure according to practical situation,not corrugating the strip
as a principle.
When the black pointer drops down the green pointer, the oil pump works
automatically. The system’s pressure is regulated through the relief valve inside the
machine.
“Pressure Relief of feed rolls”--- It’s a hand-control directional value.When the
value stem is turned to right,there’s not oil pressure to lift the feed rolls.
Note: When the machine is idling,don’t supply pressure,so as not to damage the end
of guide plate.

⑸ Run-out table
Adjust run-out tables on a suitable height. There’s a air cylinder fixed on the
shelf.After cutting,it starts to tilt the duct aside. The table must be set in the line of
duct, otherwise, forming duct may be affected.

4. Preparatory works
⑴ Fix the machine with foundation bolts.
⑵ set the run out table at suitable position and height.
⑶ examine the ground wire which connect with the distribution box. Examine the power
wire.
⑷ examine each air cylinder,whether the air pipes were inserted well. Open the air
pump,check the oil-water separator,regulate the pressure to 0.7-0.8MPa.
⑸ Add hydraulic oil (NO.46) into oil box,about 20L, watching the oil gauge,till the oil
reach top. Because the ram pump has high request to hydraulic oil’s cleanliness,
please change it termly. Add emulsion into water box(The rate of emulsion and water
is 1:10)
⑹ according to the galvanized steel’s thickness, install the correct seam locking
wheel, and adjust its position.
⑺ prepare the tools, like allen wrench, monkey wrench, shear.
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5. Operation steps:
⑴ First,cut the strip as follow, deliver the strip through the forming rolls till the feed
rolls. Then push the hand-directional valve,let the feed rolls clamp the strip.

When the metal coil is used up,you want to connect meterial,don’t do overlap welding,and
must adopt argon arc welding.

Push the hand-operated direction valve to left, let the feed rolls clamp the steel
strip.
Take up the upper guide plate, Press “Inching” button,deliver the strip. Watch the
edgefold, the male edgefold and the female edgefold should be similar size.
If the edgefolds are not same size,adjust the first roll a little,deliver the strip for a
length,then watch the edgefolds again.till the edgefold size is up to standard.then cut
off the strip in middle.
Adjust the angle of edgefold to 55 degrees
⑵ Install the mould.Raise the seam lock wheel,the top of wheel should be 1mm
higher than the inner wall of mould. Watch whether the strip’s floding and groove of
locking wheel and the mold’s helical groove are in a straight line.The locking wheel is
adjustable.
According to the mould’s helical angle,adjust the feeding angle of strip at a
general location.
⑶ open cooling system,press 【JOG】,let the strip move along the mold,after the male
edgefold insert into the female edgefold,adjust feeding angle finely,let the
edgefolds are near.
⑷ when the tube is formed,test cutting system. The cutter’s rising height is
adjustable.If the cut is helical,please adjust the angle of cutter.Now the machine can
work normally.
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⑸ Change the mould, change the current feeding angle,press ‘Inching’ to let the
locked seam tripping out,then take up the upper guide plate,cut off the strip in the
middle of plate,take out the remnant from the forming head.now you can change the
moulds.
The height of guide plate should be adjusted according to strip’s thickness. When
the steel strip is 0.6mm thick, put a 0.6mm sheet under the lower guide plate; When the
steel strip is 0.8mm thick, put a 0.4mm sheet under the lower guide plate; 1.0-1.2mm
needn’t the spacer.

⑹ Manual operation
Turn “Manual/Auto” switch to manual mode. Press the “Inching” button,the machine starts
to produce spiral tubes. If you want to cut the tube, press “Cut” button,the cutter rises,and
then press “Inching” button to begin cutting. After finishing the cutting,the cutter falls
down.When you stop working,press ‘E-stop’ button down.

⑺ Auto operation
Release ‘E-stop’ switch,press ‘running hydraulic’ button and ‘cooling’ button.Then Turn
“Manual/Auto” button to auto mode to start producing ducts.In this way,the production
speed is fast.You can rotate “working speed” rotary knob to adjust the speed.When duct
arrives the desired position and touches the sensor, machine will cut the duct automatically.
After finishing the cutting,the discharge table will turn over the duct aside. Then the cutter
falls down,and a new process begins.

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 6. Installation and Maintenance Manual

1. Machine is installed on the flat ground indoors with dry air and good ventilation.
Ambient temp: -15~40 degree C. To avoid vibration, magnetic, heat radiation
environment .
2. Electric source shall meet machine capacity. Machine ground connection shall be
reliable. Ground connection shall follow Standard. Ground connection resistance
shall be not exceeding 4Ω
3. Before operation machine, inspect all switches and buttons. If there is any problem,
remove fault at first.
4. If there any is smoke, severe vibration, abnormal sound, special smell,substantial
low motor revolution, electric shock, injures person, turn off machine immediately
to solve problems. Cut electric off after production.
5. Inspect hydraulic oil periodically. Change oil if oil is dirty, oxidized. Change hose if
it is old, broken with oil leakage. Keep oil in normal temperature in summer. Cool oil
on time. (NO.46 Hydraulic oil)

Attachment：
1、Electrical elements list
2、Hydraulic system drawing
3、Air-powered system
4、Electric diagram
5、Assembly drawing

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7. FAQ and Solution in operation
⑴ The machine doesn’t connect the ground, maybe affect the PLC’s operational
stability.
⑵ After starting up the machine,there’s no signal on the touchsreen. Please examine
whether the signal line behind the touchscreen loose.
⑶ The pipe can’t be locked, the reason may be:
① perhaps the seam lock wheel’s position is not good. The wheel’s groove should be
in a line with the guide plates’. When you set the mould, its spiral groove is also in
this line.
② Check up the feeding angle of steel strip, the male edgefold should cling to the
female edgefold.
③ The edgefolds’s angle on both sides also affect seam lock.
⑷ On the surface of duct, appear waves:
① the mould and guide plate is not in a level.
② The upper guide plate doesn’t press the steel strip closely.
③ If the waves appears when the steel strip just leave the feed rolls, show that
the pressure is too high. Or the guide plate’s crup become shorter.
④ If the waves appears in the mould, maybe the resistance of mould is big.
⑸ Hydraulic system’s pressure is unstable.
Maybe the impurity goes into the oil. Please clean the straightway check valve or
hand-operated direction valve. Also check up the electric contact gauges. If you
can't repair the parts,please change a new one.
⑹ The duct can’t be cut out.
① the air pressure is not enough.
② The under blade raised lower.
③ The space between the blades is too small or too big, it should be sheet
thickness-0.3mm.
④ The cut is helical, please adjust the blades’ angle. Please loose the 4 bolts on the
corner of U-type base, then turn the eccentric shaft to adjust the angle.

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APPENDIX:

1.Electrical elements list

Serial
Code Name Model Quantity Remarks
NO.
1 QM1,QM2 Motor breaker DZ47-63/3P/40 2 C65ND
2 QM3 Motor breaker DZ47-63/1P/C6 1 C66ND
3 SQ1 Travel switch JLXK-111 1
4 KM1/2/4 contactor CJX2-1210 220V 3
5 KM3 contactor JTX-3C 220V 1
6 KM5,KM6 contactor CJX1-9/22 220V 2
7 FR1 thermorelay JR36-20/16 1
8 FR2 thermorelay JR36-20/10 1
9 SB1 Stop button LAY7 2 OFF Red
10 SB2-13 Common buttons LA38-11BN 3
11 inverter S3100 1
12 PLC XC3-42RT-E 1
13 KA1-6 Common relay JTX-3C/220V 6
Wire connecting
14 TD-3010 1
terminal
Wire connecting
15 TD-1540 1
terminal
2.Hydraulic System Drawing

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3. Air-powered system
Air cylinder of Air cylinder of Air cylinder of
the cutter run-out table cutter reset

4.Electric diagram

1
INVERTER
2

M1 M2 M3 M4 M5

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 Long distance limit

cutter down limit

Running Hydrulic

Running Hydrulic
lower limit
Running Hydrulic
upper limit
Cutting limit
Inching
E-stop

start

Right
Left

Cut
16

KA1 KA2

2 3 4 5 6 7 8 9 10 11 12 13 14 15
L
1
N NC COM X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27
L G COM X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26

XC3-42RT-E 80 81

KA1 KA2
0V A com0 com1 com2 Y3 Y5 Y6 Y10 . com4 Y13 Y15 com5 Y17 Y21
24V B Y0 Y1 Y2 Y4 com3 Y7 Y11 . Y12 Y14 . Y16 Y20 N
60 61 62 63 65 67 68 69 70 71 73 76 78 79

KM2 KM1
KM4 KM3

64 66
74 77
KM6
L

N KA4 KA5 KM1 KM2 KM5 KM3 KM4 KA3

72 75

FR2
FR1

Inverter running
Seam lock wheel up
Seam lock wheel down
Right

Cooling
Running Hydrulic
Cutting solenoid valve up
Left

Upturn solenoid valve up

Cutting reset

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