Danfoss FT1555-BM230 Bench Mount Hose Capping System Instruction Manual
- June 13, 2024
- Danfoss
Table of Contents
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.
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
**** 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
Safety Symbols for the UC-CSS-203V-AK
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 | Avoiding | Warning Symbol |
|---|---|---|
| The Air Knife will become hot and could cause burns to the skin | Do NOT touch | |
| while machine is in operation or immediately after use, allow to cool. |
Burning fingers at operating temperature in the Air Knife FT1555-BM230 176˚C 350°F| Do NOT stick fingers into the Air Knife while in use.|
Description and Operating Procedures
Product Views (Front / Back / Side)
Features & Benefits
- Applies heated air to shrink CapSeal Capsules onto fitting ends in less than one second
- Designed for CapSeal Capsules from 14mm ID through 80mm ID
- Works with fitting hex sizes from 10mm through 78mm or any 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.
- Magnetic Puck holds the Capsule onto the fitting for a perfect seal during the shrinking process (Small 40mm / Large 64mm)
- Magnetic Puck pulls the swivel nut forward on 90° and 45° fittings for easy insertion into the Air Knife for capsule shrinking
- Heating unit is thermocouple protected against overheating
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|
FT1555-BM230
---|---
WARM-UP TIME (MIN)| SEAL TIME (SEC)
1| 3.5
2| 2.5
3| 2
4| 1.5
5| 1.25
6| 1
7| 1
8| 0.75
9| 0.75
10| 075
Capsule Application Process
-
Place correct size CapSeal Capsule on the end of hose or tube fitting. *Reference Size Chart.
-
Place magnetic puck onto the end of fitting. Slowly move fitting through the Air Knife until capsule is completely shrunk.
-
Inspect fitting to ensure CapSeal Capsule has shrunk properly.
-
Pull Tear Strip to remove CapSeal Capsule from fitting.
CapSeal Capsule Sizing Chart
SIZING
| *FITTING
---|---
CAPSULE SIZES Inside Diameter x Length in MM| HEX SIZES COVERED in
mm| HEX SIZES COVERED in inches| STRAIGHT| ELBOW
14X24| 10mm to 13mm| .39″ to 051″| x| x
16X24| 12mm to 15mm| .47″ to .59″| x| x
18X24| 14mm to 17mm| .55″ to .67″| x| x
20X23| 15mm to 19mm| .59″ to .75″| | x
20X30| 15mm to 19mm| .59″ to .75″| x|
22X24| 18mm to 21mm| .71″ to .83″| | x
25X27| 18mm to 24mm| .71″ to .94″| | x
25X40| 18mm to 24mm| .71″ to .94″| x|
28X40| 22mm to 26mm| .87″ to 1.14″| x|
31X33| 24mm to 29mm| .94″ to 1.4″| | x
31X40| 24mm to 29mm| .95″ to 1.14″| x|
34X40| 27mm to 32mm| 1.07″ to 1.26″| x|
38X40| 30mm to 36mm| 1.19″ to 1.42″| x| x
43X45| 32mm to 41mm| 1.26″ to 1.61″| x| x
46X50| 34mm to 44mm| 1.34″ to 1.73″| x| x
52X60| 41mm to 50mm| 1.62″ to 1.97″| x| x
58X60| 49mm to 56mm| 1.93″ to 2.20″| x| x
67X60| 55mm to 65mm| 2.16″ to 2.56″| x| x
80X60| 64mm to 78mm| 2.52″ to 3.07″| x| x
Capsule Size Selection by Fitting
| Fitting | Capsule |
|---|---|
| -2NPT Male | 1424 |
| -4 NPT Male | 1824 or 2030 |
| -4 JIC Fern | 1624, 1824 or 2030 |
| -4 JR, Fem YU | 1824 or 2023 |
| 4 Flat Face Fern | 2030 |
| -4 Flat Face Fern 90 | 2023 |
| -5 JIC Fern | 2030 |
| -6 NPT Male | 2030 |
| -6 JIL Fem | 2540 |
| -6 JIC Fern 90 | 2527 |
| -6 Flat Face Fern | 2540 |
| -6 Flat Face Fern 90 | 2527 |
| -8 NPT Male | 2840 |
| -8 JIL Fem | 284U |
| -8 JIC Fern 90 | 2840 |
| -8 1TC Fern 90 | 2527 |
| -8 Flat. Face Fern | 2840 |
| -8 Flat Face Fern 90 | 2840 |
| -8 Flange Lode 61 | 3133 or 314U |
| -8 Flange Code 62 | 3440 |
| -10 lIC FPM | 3140 |
| -10 JIC Fern 90 | 3133 |
| -10 Flat Face Fern | 3110 |
| -10 Flat Face Fern 90 | 3440 |
| -10 Komatsu Flange | 3840 |
| -12 NPT Male | 3140 |
| -12 JIC Fern | 3840 |
| -12 JIC Fern 90 | 3810 |
| -12 Flat Face Fern | 4345 |
| -12 Flat Face Fern 90 | 4345 |
| -17 Flange Code 61 | 3840or 4345 |
| -12 Flange Code 62 | 4345 |
| -16 NPT Male | 4650 |
| -16 JIC Fern | 4650 or 5260 |
| -16 JIC Fern 90 | 4650 or 5260 |
| -lb Flat Face Fern | 4650 or 5260 |
| 16 Flat Face Fern 90 | 4650 or 5260 |
| -16 Flange Code 61 | 4650 |
| -16 Flange Code 62 | 5260 |
| -20 NPT Male | 5260 |
| -2U JIG hem | 5860 |
| -20 Flat Face Fern | 5860 |
| -20 Flange Code 61 | 5860 |
| -20 Flange Code 62 | 5260 |
| -24 NPT Male | 6760 |
| -24 JIG hem | 5860 |
| -24 Flat Face Fern | 8060 |
| -74 Flange Code 61 | snAn |
| -24 Flange Code 62 | 6760 |
| -32 NPT Male | 6760 |
| -32 JIG hem | 8060 |
| -32 Flange Code 61 | N/A |
| -37 Flange Code 67 | 8060 |
Specifications
| Item | Specification |
|---|---|
| Machine Dimensions (w x d x h) FT1555-BM230 | 254 x 584.2 x 279.4 mm |
| Weight (net) FT1555-BM230 | 9.57 Kg / 21.1 lbs |
| Voltage | 230-240 VAC 50/60 Hz |
| Max Power consumption | 3400W |
| Current | 14.78 Amps |
| Set Temperature Heat Gun FT1555-BM230 | 330 °C / 631 °F |
| Exterior temperature housing FT1555-BM230 | 60-80 °C / 140-175 °F |
| Duty Cycle | 100% |
| Noise Emission | <65 dB(A) |
| Heating element life | Approx. 500-800 hrs. |
| Electrical Connection Requirement | 230-240V, 15 Amp, Grounded L6-15 NEMA twist |
lock
Wiring Diagram 230V-AK
Machine Plate
The Machine plate is located on the back side of the machine, left of the power cord.
FT1555-BM230 Exploded View
FT1555-HH-AK20 Exploded View
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.
-
Turn off the power switch. Disconnect the FT1555-BM230 from the power source and remove the unit from service.
-
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.
-
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.
-
Remove the 4 screws that hold the filter base in place, using a 2mm or 5/64” Allen Wrench (not included)
-
Use a coarse brush (not included) for removing any debris from the heating elements’ air intake grill that could obstruct air flow.
vacuum cleaner with brush attachment is also acceptable for cleaning. -
Reinstall the foam filter and retainer.
-
Return the FT1555-BM230 to service (see page 4)
Troubleshooting
| Problem | Cause | Solution |
|---|---|---|
| Capsule does not fit properly | Wrong diameter capsule for application | Measure |
outside diameter of the fitting and use advised capsule.
Capsule doesn’t shrink| Machine is turned off/ Not heated to max temp.| Turn
on machine as described in section 2.4 Reference Time chart on page 7
Capsules melt during shrinking| Temperature is too high.| Check foam filter
and air inlet of the Heat gun.
process| Holding capsule in the AK for more than 5 seconds| Clean both filters
as described under 3.1. Check temperature settings. Display on heat gun should
read as follows:
FT1555-BM230 325-330ºC
Unit doesn’t blow air| Faulty electrical Overheating| 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 | Description | Exploded view # |
|---|---|---|
| 230V-AK | 2.0 AK | |
| UC-HG5000E | HG5000E 230V Heat Gun | 6 |
| UC-1955K22 | CSS- Plastic Fan Guard with Filter Insert | 12 |
| UC-2572K25 | CapSeal System Bumper Feet | 13 |
| FT1555-SMP | Small Puck | |
| FT1555-LMP | Large Puck |
CapSeal Capsule Sizing Chart
Modifications
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.
Please call Danfoss with any questions regarding the safe operation of the FT1555-BM230.
Disposal
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.
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
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
Danfoss Power Solutions ApS
Nordborgveg 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
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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.
References
- Engineering Tomorrow | Danfoss
- Danfoss' businesses - Engineering since 1933 - Explore innovative solutions for many markets | Danfoss
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