RBE-200 - Apex Power Tools
Contents
1. Dip the expander in the bead tube lubricant and re insert the expander into the tube Expand the tube until the mandrel s hub comes into contact with the mandrel thrust plate 21 and makes a few revolutions to iron out the bead You will notice an increase in the drive motor s RPM when the bead is finished If the bead is not completely pressed up to the tube sheet rotate the adjustment sleeve 1 1 2 revolutions and re expand the tube If this does not pull the bead up to the sheet then there may be too much tube projection Reduce the projection on another tube by 1 32 and expand that tube Ifthe tubes you are roller bead expanding are just shy of being completely pressed to the tube sheet then expand all the tubes with this adjustment setting Increase the setting after all the tubes have been expanded Re expand only the tubes that the bead is not pressed against the tube sheet Re expanding tubes with the roller beading expander that have the bead completely pressed against the tube sheet will put extreme side load on the expander and reduce the expanders life Remember to always dip and flush the expander into the bead lube to clean and cool the ex pander after each expansion The expander s mandrel is equipped with a square on the front so the expander s drive motor can be used in reverse when expanding the internal tube sheet in the boiler A WARNING Never attempt to expand the internal tube sheet by reaching through the combusti2. Tel 425 497 0476 Fax 425 497 0496 England Cooper Power Tools GmbH amp Co OHG a company of Apex Tool Group LLC C O Spline Gauges Piccadilly Tamworth Staffordshire B78 2ER United Kingdom Tel 44 1827 8741 28 Fax 44 1827 8741 28 Brazil Cooper Tools Industrial Ltda a company of Apex Tool Group LLC Av Liberdade 4055 Zona Industrial Iporanga 18087 170 Sorocaba SP Brazil Tel 55 15 2383929 Fax 55 15 2383260 90126 IM Printed in USA 05 2011 Copyright O Apex Tool Group LLC Houston TX Apex Tool Group Sales amp Service Center 6550 West Sam Houston Parkway North Suite 200 Houston TX 77041 Tel 713 849 2364 Fax 713 849 2047 York PA Apex Tool Group Sales amp Service Center 3990 East Market Street York PA 17402 Tel 717 755 2933 Fax 717 757 5063 France Cooper Power Tools SAS a company of Apex Tool Group LLC 25 rue Maurice Chevalier 77330 Ozoir La Ferriere France Tel 33 1 6443 2200 Fax 33 1 6443 1717 Hungary Cooper Tools Hungaria Kft a company of Apex Tool Group LLC Berkenyefa sor 7 Pf 640 9027 Gy r Hungary Tel 36 96 66 1383 Fax 36 96 66 1135 Lexington SC Apex Tool Group 670 Industrial Drive Lexington SC 29072 Tel 800 845 5629 Tel 803 951 7544 Fax 803 358 7681 Canada Apex Tool Group Sales amp Service Center 5925 McLaughlin Road Mississauga Ont L5R 1B8 Canada Tel 905 501 4785 Fax 905 501 4786 China Cooper C
3. 2900585 Bead Lube 2900585 Bead Lube 2900585 A SS So a OO NO 0 PD N a a all all al One roll is sent as a spare Not shown Notes Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Apex Tool Group Sales amp Service Center 1470 Post amp Paddock Grand Prairie TX 75050 Tel 972 641 9563 Fax 972 641 9674 Los Angeles CA Apex Tool Group Sales amp Service Center 15503 Blackburn Avenue Norwalk CA 90650 Tel 562 623 4457 Fax 562 802 1718 Germany Cooper Power Tools GmbH amp Co OHG a company of Apex Tool Group LLC Industriestra e 1 73463 Westhausen Germany Tel 49 0 7363 810 Fax 49 0 73 63 81 222 Mexico Cooper Tools de M xico S A de C V a company of Apex Tool Group LLC Vialidad EI Pueblito 103 Parque Industrial Quer taro Queretaro QRO 76220 Mexico Tel 52 442 211 3800 Fax 52 442 103 0443 Apex Tool Group LLC 1000 Lufkin Road Apex NC 27539 Phone 919 387 0099 Fax 919 387 2614 www apextoolgroup com Detroit MI Apex Tool Group Sales amp Service Center 2630 Superior Court Auburn Hills MI 48326 Tel 248 391 3700 Fax 248 391 7824 Seattle WA Apex Tool Group Sales amp Service Center 2865 152nd Avenue N E Redmond WA 98052
4. B 1158 RR 2993548 B 1205 RR 2993659 B 1276 RR 2993662 Roll Retainer RBE 200 2998686 RBE 250 2998696 RBE 300 2998743 Long Roll RBE 200 LR 2900368 RBE 250 LR 2900369 RBE 300 LR 2900370 Short Roll RBE 200 SR 2998705 RBE 250 SR 2998706 RBE 300 SR 2998753 Beading Roll RBE 200 156 2998665 RBE 250 156 2998666 RBE 300 156 2998667 Cage RBE 200 2998685 RBE 250 2998695 RBE 300 2998742 Thrust Plate RBE 200 TP 2998694 RBE 250 TP 2998704 RBE 300 TP 2998751 Plate Bearing RBE 200 PB 2900374 RBE 250 PB 2900375 RBE 300 PB 2900376 Thrust Bearing D 16 2973171 D 20 2900381 D 25 2900382 Thrust Stem RBE 200 TS 2998693 RBE 250 TS 2998703 RBE 300 TS 2998750 Brass Tip Set Screw 1 4 20 X 1 4 BT 8010931 1 4 20 X 1 4 BT 8010931 1 4 20 X 1 4 BT 8010931 Retaining Collar RBE 200 2998687 RBE 250 2998697 RBE 200 2998744 Spring RBE 200 SPR 2998689 RBE 250 SPR 2998699 RBE 300 SPR 2998746 Spring Stop RBE 200 SPS 2998688 RBE 250 SPS 2998698 RBE 300 SPS 2998745 Retaining Ring US 175 2900474 US 212 2998762 US 250 2900612 Set Screw 1 4 20 X 1 4 8006600 1 4 20 X1 4 8006600 1 4 20 X 1 4 8006600 Adjustment Sleeve RBE 200 AS 2998690 RBE 250 AS 2998700 RBE 300 AS 2998747 Mandrel Bearing RBE 200 MTB 2998692 RBE 250 MIB 2998702 RBE 300 MTB 2998749 Mandrel Thrust Plate RBE 200 MTP 2998691 RBE 250 MTP 2998701 RBE 300 MTP 2998748 Ret Ring 5 8 2120600 11 2001200 B 1355 RR 2994211 Mandrel RBE 200 RM 2900497 RBE 250 RM 2900498 RBE 300 RM 2900499 Bead Lube Bead Lube
5. Operating amp Service Manual 90126M Airetool RBE Series Roller Beading Expanders Replacement Rolls Expander Fart Number Tube Size Mandrels Fare Number Part Number Expanding Part Number Order Order Beading Roll Order Roll Set Order RBE 200 5524418 2 RBE 200 RM 2900497 RBE 200 156 2998665 RBE 200 ERS 5524419 RBE 250 5524420 2 1 2 RBE 250 RM 2900498 RBE 250 156 2998666 RBE 250 ERS 5524421 RBE 300 5524422 RBE 300 RM 2900499 RBE 300 156 2998667 RBE 300 ERS 5524423 Note Expanders are sold with Mandrel For additional product information visit our website at http www apextoolgroup com Operation The Airetool Patented Roller Beading Expanders are designed to expand and bead firetube boiler tubes in one operation This expander eliminates the secondary operation of beading the tube with a chipping hammer and beading chisel The expander reduces shop noise levels and operator stress thus increasing overall productivity Tube Projection The tubes must have a uniform projection from the tube sheet of 3 16 9 32 4 75mm 7 1mm prior to beading the tube with the Airetool roller beading expander The tubes must be staked or clamped at one end of the boiler with the opposite end having the 3 16 9 32 tube projection To obtain the tube projection from the end of the boiler where the tubes were staked or clamped an internal wheel type boiler tube cuter must be used with the tube cutter s collar positioned to
6. hina Co Ltd a company of Apex Tool Group LLC 955 Sheng Li Road Heqing Pudong Shanghai China 201201 Tel 86 21 28994176 Fax 86 21 51118446 Airetool
7. obtain the tube projection Reference Airetool series FTC Firetube Cutters for accom plishing this task Failure to comply with the recommended tube projection will cause extreme side load pressure and reduce the expander s life Lubrication The tubes and the roller beading expander must be clean and free of any debris prior to expanding The Airetool beading expander is sold with lubrication we call bead lube This is the only lubrication that is to be used during the expanding process This lubrication is water soluble and is to be mixed with water at approximately twenty water to one lubrication ratio After each expansion place the expander in the bucket of lubricant and swish it around until all the debris has been removed from the expander roller cavity areas The expander must be kept cool and clean or the beading roll will start galling the bead making it unacceptable This extreme heat will also decrease the expander s life Beading Expander Set up Measure the tube sheet hole ID tube ID tube OD and the tube wall thickness Then subtract the tube OD from the tube sheet ID this will give you the clearance between the two Then multiply the tube wall thickness by two and again by 10 this is the expansion at 10 wall reduction Next add the clearance the wall reduction calcu lation to the non expanded tube ID This will give you the expansion of the tube at 10 wall reduction See the chart below for additional reference e Ste
8. on access hole The Airetool beading expander generates great force and could cause injury to the operator Always roll the internal tube sheet with an extension to drive the expander from the opposite end of the boiler Maintenance Inspect the mandrel and rolls on a continuous basis Any time pitting or extreme wear is observed replace these parts immediately to avoid damage to other expander components After each shifts production completely dissemble the expander and wash all parts thoroughly with a solvent such as mineral sprits To disassemble remove mandrel 23 from expander remove retaining clip 1 and remove cage ring 2 remove retaining ring 3 pull roll retainer 4 from cage 8 loosen set screw 18 and unthread adjustment sleeve 19 remove retaining ring 22 and remove mandrel bearing 20 and mandrel thrust plate 21 remove retaining ring 17 and remove spring stop 16 spring 15 and retaining collar 14 loosen set screw 13 place nose of cage 8 in a vise and unthread thrust stem 12 from cage 8 left hand thread remove bearing 11 and thrust plate 9 After all parts have been thoroughly cleaned apply grease to bearings 10 11 and 20 and re assemble the tool in reverse order y o d AIRETOOL RBE SERIES ROLLER BEADING EXPANDER PARTS LIST item No TRIERER ee Ret Ring US 137 2900473 US 187 2900475 US 225 2900476 Cage Ring RBE 200 CR 2900371 RBE 250 CR 2900372 RBE 300 CR 2900373 Ret Ring
9. p A Measure tube sheet hole e StepB Measure tube OD e Step C Calculate clearance A B e StepD Measure tube ID e StepE Calculate wall thickness B D e StepF Calculate 596 wall reduction 10 x E e StepG Calculate finished rolled ID C D F JOINT Tube Sheet Hole Tube OD 2 000 Clearance 032 Tube ID 1 810 2 x Wall Thickness 190 10 Wall Reduction 019 Finish Rolled ID 1 861 Beading Expander Set up continued After determining the final rolled ID insert the expander into the tube that is to be beaded Insert the mandrel into the expander then tap the mandrel s end slightly with a hammer until the expander s rolls come in contact with the tube ID Per the example above we are expanding the tube s ID 051 to obtain the 10 wall reduction For each 1 of mandrel travel we obtain 041 in expansion therefore by dividing the total expansion 051 by 041 1 244 or 1 1 4 will give you the distance the mandrel needs to travel to obtain the calculated expansion Now knowing the distance the mandrel needs to travel we are able to adjust the tool for the proper expansion Loosen the set screw 18 then move the adjustment sleeve 19 by rotating it so you have an 1 1 4 distance between the mandrels shoulder and the mandrel thrust plate 21 Then re secure the set screw 18 See the illustration below ze lt 1 1 4 You are now ready to expand the first tube
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