Work Instruction

WI/D/COIL/05

Title : Set up procedure for Fin press

Date : 25/12/07

Prepared By :

Revision : 01
Page : 1 of 1

Approved By :

SET UP PROCEDURE FOR SLIT FINS TO PLAIN FINS

( DEACTIVATE ENHANCE STATION )
1. Inch the press to the top of the stroke, raise the crown, and shut the press off.
2. Remove all the mounting bolts from the interior of the upper station.
Do not remove the two end bolts on each end at this time.
3. Loosen the two bolts at each end. ( Only loosen dont remove )
4. Remove the two gag bars from the top of the upper enhance station.
5. Tighten the two bolts on each end alternate from end to end.
6. Similarly install & tighten all upper-mounting bolts.
7. Check that all bolts are tight & then lower crown.
SET UP PROCEDURE FOR PLAIN FINS TO SLIT FINS
( ACTIVATE ENHANCE STATION )
1. Inch the press to the top of the stroke, raise crown, and shut the press off.
2. Loosen the two end mounting bolts (both ends ) by Two turns only.
3. Loosen & remove the interior mounting bolts.
4. Install ball cages on lower ENHANCE Station.
5. Start the press, lower crown, inch to bottom of stroke.
6. Shut the press off, remove remainder of mounting bolts.
7. Start the press, inch to top, raise crown, shut the press off.
8. Insert the two gag bars on top of the upper enhancement station.

9.
10.
11.
12.
13.
14.

The slot faces to the outside and must align with mounting holes in the
upper station. Make sure all mounting holes align with a slot and that
edge of the bars are even with the edges of the upper station.
Lower crown, inch to bottom of stroke, stop press.
Insert & tighten two end-mounting bolts on each end.
Inch to top of stroke , raise crown , stop press.
Insert the remainder of the upper mounting bolts & tighten.
Remove the ball cages from upper enhance station.
Check all bolts for tightness.

NOTE : On New Fin Press, Keep Enhance switch ON position while puching slit fins
and put OFF while punching plain fins.

Revision Record
Previous Revision
No
1

Page No

Revision Description
Note added

WI/D/COIL/03

Work Instruction
Title : BULLET SIZE FOR EXPANDER
Prepared By :

Date :10/09/08
Revision : 02
Page : 1 of 1

Approved By :

Hair pins and straight tubes for fin and tube coils shall be expanded such as to cause
the OD of the tube to be 0.004 larger than the fin hole ID

The wall thickness of the tubing does not change appreciably during the expansion.
the change is in the length . The table below shows the desired tube expanded size
and recommended bullet size for various tube size and wall thickness .

Tube Size
( Nominal ) OD
3/8 inner
Groove 0.039
Wall thick(Reg
Cu)
3/8 inner
Groove 0.039
Wall thick( Low
Wt Cu)

Fin Hole
Diameter
( inch)
0.389(+/-)
0.001

Expanded Tube
OD ( Inch )

Bullet Size OD (
inch )

0.392/0.393

0.358/0.357

0.389(+/-)
0.001

0.392/0.393

0.362 TO 0.361

Maintenance of Bullets
Once every month all the bullets in usage will be checked by Micrometer for the
diameter . the undersized bullet will be discarded .

Revision Record
Previous Revision
No
01
02

Page No
1
1

Revision Description
Plain tube removed
Low wt copper added

Work Instruction
Title : Set up procedure for Mech. Expander

Prepared By :

Approved By :

WI/D/COIL/08
Date : 10/02/07
Revision : 00
Page : 1 of 2

SET UP PROCEDURE FOR MECH. EXPANDER M/C.

1.0 MOUNTING OF TOOLING PLATES
While changing setting from smaller coil to longer coil , first set the require fin length.
Determine how many plates will be needed for final coil length. Then mount the doorplates & back plates with minimum distance between two.
Set the doorplate as per no. of rows. of coil.
While changing setting from longer coil to smaller coil , first determine how many plates
Will be needed for final coil length & then remove the doorplates & back plates which are
not needed.. Now set the fin length of coil & tighten doorplates as per no. of rows of coil .
Mount the plates with minimum distance between two.
2.0 EXPANDER BULLETS
(1) Bullets may be assembled to the expander rod before it is mounted in the machine.
(2) If the expander rods are in machine , JOG DOWN until the stripper and expander
Heavy plates are resting on the holding blocks and the end of the expander rods
are atleast 2 inches below the pushers.
(3) Screw a bullet on to the end of rod. Hold the rod and tighten the bullet screw.
3.0 RECEIVERS
Set dowel end into desired holes in the receiver plate and push into place with plastic
hammer.
4.0 COIL LENGTH
(1) Using JOG UP or JOG DOWN move the heavy plates and holding block until the
distance between hairpin receiver and stripper tool is equal to the length of a
finished coil over the tube-sheets.
(2) When measurement is correct tighten the bolts on holding blocks securely.
(3) Remove the pick up plates from the stripper plate bushing housing.
(4) Open lift & JOG DOWN until the ram cylinder bottoms. When the ram cylinder
bottoms the pressure plate is at lowest position.
(5) While holding the JOG DOWN push button , turn the keyed COIL LENGTH
switch to SHORT to raise the pressure screws to the pressure plates.
(6) When the screw solidly contact the plate a clutch in the gear motor will slip ,
indicating that the screws are properly set against the pressure plate.
When slippage occurs release both switches.
(7) JOG UP the plates until the cylinder has retracted completely.

Work Instruction
Title : Set up procedure for Mech. Expander

Prepared By :

Approved By :

WI/D/COIL/08
Date : 10/02/07
Revision : 00
Page : 2 of 2

5.0 EXPANDER ROD & STRIPPER TOOL

Load expander rod with final expander tips and bullets into the m/c. as required.
Place stripper tube at each tube position. One or two stripper tool may be removed from
front row of pattern so that tube sick out and bullet entry into tube may be observed
during expansion.
6.0 COIL ALIGNMENT AND PRE-SIZE ADJUSTMENT
(1)
(2)
(3)
(4)

Load an unexpanded coil onto the lift and push the hairpins into the receiver nest.
Close lift & jog down the ram cylinder until the stripper are approxly 50 mm away
from the tubes. INCH DOWN the ram cylinder and align coil with stripper tubes.
INCH DOWN the stripper tube up to required stick out of coils & then tight the
Pre-size block against the bottom of blocks.
Move coil locator s so that they are in contact with coil & tight it.

Revision Record
Previous Revision
No

Page No

Revision Description