Continental Refrigerator PC440i Series User manual

Group or Division Here
www.contitech.us
Industrial Fluid Solutions
PC440i Crimper
with CrimpIQ™ Controller
Operator Manual
www.contitech.us

2PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
PC440i Safety Precautions......................................................................................................................................................................................................................................................................................................................4
PC440i Initial Crimper Setup................................................................................................................................................................................................................................................................................................................. 5
High-Level CrimpIQ™ Controller Capabilities...................................................................................................................................................................................................................................................................6
CrimpIQ™ supports the following features.............................................................................................................................................................................................................................................................6
PC440i Series ............................................................................................................................................................................................................................................................................................................................................................7
PC440i Features ....................................................................................................................................................................................................................................................................................................................................................8
Initial Crimper Setup.........................................................................................................................................................................................................................................................................................................................................9
Overview.........................................................................................................................................................................................................................................................................................................................................................9
Crimper Operations.......................................................................................................................................................................................................................................................................................................................................10
Logging In.................................................................................................................................................................................................................................................................................................................................................10
Default User Accounts................................................................................................................................................................................................................................................................................................................10
Navigating the CrimpIQ™ Controller.......................................................................................................................................................................................................................................................................................11
Basic Application Guide............................................................................................................................................................................................................................................................................................................11
Top Menu...................................................................................................................................................................................................................................................................................................................................................11
Left Slide-Out Menu Functions.........................................................................................................................................................................................................................................................................................12
Left Slide-Out Menu Information....................................................................................................................................................................................................................................................................................12
Using the Main Menu...................................................................................................................................................................................................................................................................................................................................13
CrimpIQ™ controller Main Menu Screen Options......................................................................................................................................................................................................................................13
Crimper Operations.......................................................................................................................................................................................................................................................................................................................................14
Main Crimper Operations Screen.................................................................................................................................................................................................................................................................................14
Load Crimp Speciications.....................................................................................................................................................................................................................................................................................................14
MyCrimp® – Search Screen...................................................................................................................................................................................................................................................................................................15
Key Functions of MyCrimp®................................................................................................................................................................................................................................................................................................15
MyCrimp® – Results Screen..................................................................................................................................................................................................................................................................................................16
MyCrimp® – Crimp This Speciication ......................................................................................................................................................................................................................................................................17
Managing Crimp Speciications ......................................................................................................................................................................................................................................................................................17
Crimp Speciications with Special Handling Requirements...........................................................................................................................................................................................................18
Favoriting Crimp Speciications ....................................................................................................................................................................................................................................................................................................19
Editing a Favorite ..............................................................................................................................................................................................................................................................................................................................20
Favorite Special Handling.......................................................................................................................................................................................................................................................................................................20
Crimp to Diameter...........................................................................................................................................................................................................................................................................................................................................21
MyCrimp® Industrial......................................................................................................................................................................................................................................................................................................................................22
Entering Industrial Measurements..............................................................................................................................................................................................................................................................................22
Beginning a Crimp...........................................................................................................................................................................................................................................................................................................................................24
Loading Dies...........................................................................................................................................................................................................................................................................................................................................24
Selecting a Die......................................................................................................................................................................................................................................................................................................................................25
Change Die Mode............................................................................................................................................................................................................................................................................................................................26
Crimp Operations.............................................................................................................................................................................................................................................................................................................................................27
Performing the First Crimp...................................................................................................................................................................................................................................................................................................27
Measuring a Crimp.........................................................................................................................................................................................................................................................................................................................28
Crimp Operations Screen .......................................................................................................................................................................................................................................................................................................29
Crimp Operations Screen Sections.............................................................................................................................................................................................................................................................................29
Operational Information ..........................................................................................................................................................................................................................................................................................................30
Crimp Detail Panel...........................................................................................................................................................................................................................................................................................................................30
Crimp Mode............................................................................................................................................................................................................................................................................................................................................32
Crimp Information...........................................................................................................................................................................................................................................................................................................................33
Crimp Management Function Buttons ..................................................................................................................................................................................................................................................................34
Table of Contents
Table of Contents

3PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Settings and Support...................................................................................................................................................................................................................................................................................................................................35
Machine Coniguration..............................................................................................................................................................................................................................................................................................................36
Machine Coniguration Options......................................................................................................................................................................................................................................................................................36
Managing Preset Dies.................................................................................................................................................................................................................................................................................................................37
Managing Users.................................................................................................................................................................................................................................................................................................................................38
Self Calibration Mode...................................................................................................................................................................................................................................................................................................................38
Default User Accounts...............................................................................................................................................................................................................................................................................................................38
Maintenance Mode........................................................................................................................................................................................................................................................................................................................39
Setting Up an Internet Connection.............................................................................................................................................................................................................................................................................39
Using an Ethernet Connection.........................................................................................................................................................................................................................................................................................39
Using a Wi-Fi Connection........................................................................................................................................................................................................................................................................................................40
Connecting to a Captive Portal........................................................................................................................................................................................................................................................................................40
Verifying Connection Status................................................................................................................................................................................................................................................................................................40
Testing Proper Connectivity................................................................................................................................................................................................................................................................................................41
Additional Connection Options.......................................................................................................................................................................................................................................................................................41
Internet Access Requirements .........................................................................................................................................................................................................................................................................................41
Backup to CrimpCloud®............................................................................................................................................................................................................................................................................................................42
General Coniguration.................................................................................................................................................................................................................................................................................................................42
Support..........................................................................................................................................................................................................................................................................................................................................................................45
Create a Ticket......................................................................................................................................................................................................................................................................................................................................46
What Happens Next?...................................................................................................................................................................................................................................................................................................................46
Conti Fluid Solutions.....................................................................................................................................................................................................................................................................................................................47
Training Manuals...............................................................................................................................................................................................................................................................................................................................47
Machine Information....................................................................................................................................................................................................................................................................................................................47
Other Topics............................................................................................................................................................................................................................................................................................................................................................48
Integrated Caliper Measurements ...............................................................................................................................................................................................................................................................................48
Coniguring CrimpIQ™ Calipers (Bluetooth).....................................................................................................................................................................................................................................................48
Coniguring CrimpIQ™ Calipers (USB).....................................................................................................................................................................................................................................................................48
Setting Up USB Calipers...........................................................................................................................................................................................................................................................................................................48
Using CrimpIQ™ Calipers.........................................................................................................................................................................................................................................................................................................49
PC440i Lubrication Procedure ......................................................................................................................................................................................................................................................................................................50
PC440i Die Installation and Management ......................................................................................................................................................................................................................................................................51
Adapter Die Installation..............................................................................................................................................................................................................................................................................................................51
Hydraulic Die Installation......................................................................................................................................................................................................................................................................................................... 52
PC440i PLC Reset Procedure............................................................................................................................................................................................................................................................................................................53
Resetting the PLC to Its Original Settings ........................................................................................................................................................................................................................................................... 53
PC440i Troubleshooting.........................................................................................................................................................................................................................................................................................................................54
PC440i Component Parts Breakdown..................................................................................................................................................................................................................................................................................55
PC440i Warranty...............................................................................................................................................................................................................................................................................................................................................61
CustomCrimp® “No Nonsense” Warranty............................................................................................................................................................................................................................................................61
Table of Contents

4PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
SAFETY PRECAUTIONS
• Read instructions and identify all component parts before using the crimper.
• PC440i crimper can produce 265 tons of crimping force.
• Keep both hands away from pinch points.
• Consult the Continental Crimp Speciications Manual for correct crimper setting
and crimp measurements.
• Always wear eye protection.
i
PC440i Safety Precautions

5PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
PC440i Initial Crimper Setup
Hydraulic Oil Check: Check the hydraulic oil level in the sight
glass window on the front of the reservoir.
Notes:
• The reservoir requires 8 gallons of ISO grade 46 hydraulic
oil for complete ill.
• If necessary, oil can be drained from either of the two ports
at the bottom of the reservoir.
Voltage Tag Check: Check electrical circuit to be certain that
it matches the crimper’s requirements
shown on the voltage tag attached to the
crimper cord.
Notes:
• Plug the PC440i crimper directly into the appropriate electrical circuit/wall outlet.
• Electrical Requirements:
7.5HP/230V/3Phase (20 Amp)
7.5HP/440V480V/3Phase (20 Amp)
5HP/230V/1Phase (30 Amp)
Caution: Do not run the crimper on an extension cord as low voltage
can damage the motor and/or electrical components.
Rotation of the Motor Check to be certain that the motor rotates
Check: in the direction of the arrow shown on the
motor housing.
Caution: Damage to the pump can result if the motor does not rotate
in the correct direction.
PC440i Initial Crimper Setup

6PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
High-Level CrimpIQ™ Controller Capabilities
High-Level CrimpIQ™ Controller Capabilities
This version of the CrimpIQ™ controller is designed to take full advantage of the tablet interface and the connection to
CrimpCloud®. CrimpCloud® is a web portal that provides users access to crimping and quality results captured in the
CrimpIQ™ controller.
CrimpIQ™ Supports the Following Features
Ease of Use:
• Quick access to simple hydraulic and industrial crimping modes.
• Optional semi and full automatic crimping modes.
• New touchscreen interface with clear, easy to read icon driven operations.
• Integrated measurement tools: Choice of USB wired or Bluetooth caliper provide direct measure
input for crimp, diameters and industrial hose measurements.
• Integrated help and tutorial guides for easy feature reference.
• Ability to easily favorite crimp speciications, complete with notes, for easy reference and accurate repeat crimping.
• Ability to track and report on crimp measurements and crimp pressures.
Integrated Crimping Tools:
• Full integration with MyCrimp®, for easy importing and handling of full crimp speciications.
• Integrated Industrial Crimp Calculator computes appropriate crimp diameter based on hose and itting measurements.
• Support for foot pedal and electronic backstop.
Customizable:
• User account speciic settings, such as choice of millimeters or inches as irst choice for data entry.
• Create individual user logins (4-digit pins) to track usage and restrict machine coniguration.
Connected:
• Wi-Fi or Ethernet connections, for easy reference to manufacturer web content straight from the crimper,
automatic coniguration backup and operations tracking.
• Ability to wirelessly update crimper software, providing up-to-date crimp speciications and new
functionalities to crimper software.
• CrimpCloud® reporting to provide various reports on assemblies, crimps and machine maintenance.
Integrated Support and Maintenance:
• Simple on-crimper support ticket creation, with enhanced technical diagnostics for quicker and more responsive
help when needed most.
• Built-in tutorials and training, including feature tutorials on every screen.
• Dynamic machine maintenance tracking and reporting, showing historical tracking of maintenance.
• Preventive maintenance alerts avoid machine downtime and costly repairs.
• Detailed on-machine availability of machine capacities.
Expansion Options:
• Bluetooth 4.0 supports Bluetooth calipers and other approved accessories.
• 8GB on-device storage, for support of crimp speciications or other future applications.

7PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
PC440i Series
PC440i Series
PC440i Speciications
Crimping force: 265 Ton
Hose capacity: Max 2SP: 2", 4SP: 2", 6SP: 1-½", Industrial: 4"
Size: L: 46-½" x W: 52" x H: 67"
Weight: 1,840 lbs.
Power: 7.5HP/230V/3Phase (Standard) 7.5HP/440V-
480V/3Phase (Optional) 5HP/230V/1Phase (Optional)
Hydraulic die series: 99P
Adapter die series: 160MM to 99MM
Industrial die series: 160S
Adjustability: Inch/Metric
Opening w/o dies: 248mm/9.75"
Master die inside diameter: 160mm/6.3"
Master die travel: 102mm/4"
Reservoir capacity: 8 U.S. Gallons
Oil type: ISO 46 Hydraulic Oil
67"
52"
46-½"
Electrical
Enclosure
7.5 HP Motor High
Capacity Pump
CrimpIQ™ Controller
99P Die Series
Foot Pedal for Use in Semi
and Full Automatic Mode
Adjustable Mirror
Back Shelf
Reservoir
Small Footprint for
Minimum Use of Space
Crimper Head Close Button
Adjustable Arm
Crimper Head Open Button
Emergency Stop
Audio and USB Ports
Built-in Die Storage Pockets

8PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
PC440i Features
Quickly Interchangeable
Adapter Dies.
Continental CrimpIQ™ controller, the
future of crimping at your ingertips.
10-inch color capacitive touchscreen
and user- friendly navigation.
Intuitive screens lead the operator
through the setup and crimping process.
Quick change tool makes die
changes a quick and simple process.
Fixed 6 o’clock die position allows
the operator to place the itting on
bottom die and crimp.
Manual backstop makes hydraulic hose
production crimping fast and accurate.
Built-in die storage pockets keeps
frequently used die sets readily available.
Foot pedal for use in semi and full
automatic mode.
PC440i Features

9PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Initial Crimper Setup
Overview
Before the crimper can be used for the irst time, a brief setup process must be completed. This process sets some initial
parameters, identiies this machine to the CrimpCloud® system and allows the user to conirm the Terms and Conditions
for use of this machine.
This process only needs to be completed once when the machine is installed. After that, the machine will power up and
be ready for use.
Initial Crimper Setup

10 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Default User Accounts
The system comes with 3 users already created: admin, machine owner and user. Additional accounts can be added if
required using the machine coniguration menu.
Pin codes listed below are defaults, and they can be changed by machine owners in the user menu:
If you have conigured additional users, their names will appear in this list as well. Once you have logged in, you can begin
using the crimper.
Admin: A private account for certiied technicians and engineering maintenance.
Machine This account is an admin level account intended for the local administration.
Owner: It has full access to all settings and functions. Default pin code is 9876.
User: This account has the permissions and capabilities to perform crimping operations but
has limited access to settings and diagnostics/setup functions. Default pin code is 1234.
Note: The system will automatically log users out of the system after the machine is idle for 1 hour.
This feature can be disabled or conigured in the Machine Coniguration screen.
Crimper Operations
Logging In
To begin using the crimper, you must irst login.
The crimper supports multiple users to allow tracking of activities as well as restrict access to some coniguration type functions.
Crimper Operations

11PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Navigating the CrimpIQ™ Controller
This section provides an introduction to the controller screens and functions that are common throughout the application.
Basic Application Guide
This section outlines basic functions within the app that are common throughout the application. The basic outline and
functionality is common throughout the application.
The screen is divided into the following sections:
Top Menu: This area of the screen provides high-level application and controller information
and access to help and settings.
Main Screen: Main screen with information and functions related to this screen
(directly linked to the screen title).
Left Menu: Provides access to information and functions that need to be available from everywhere
within the application. Access this with the menu button or by “swiping” left to right
from the left side of the screen.
Back/Menu: This allows you to return one screen back (when you reach the main menu,
it brings out the left slide-out menu).
Information/Help: This option brings up help information relevant to the speciic location within the app.
Other: There are a few other status indicators that may be helpful.
• Right section displays Wi-Fi strength, Bluetooth status and machine time.
Main
Screen
Top
Menu
Left Menu
Access
Top Menu
The top menu includes a screen title, access to menus and information.
Back/Menu Screen Title Information/Help
Navigating the CrimpIQ™ Controller

12 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Navigating the CrimpIQ™ Controller
Left Slide-Out Menu
The left slide-out menu is available from anywhere within the Crimp controller app. It can be accessed by pressing the Menu button
(always on the lower left side) or by swiping left from the left side of the screen.
Once opened, pressing anywhere on the right side of the screen (right of the left slide-out menu) will close the menu.
The left menu contains information and functions that could be used at any time within the application.
Left Slide-Out Menu Information
The left slide-out menu provides a quick status of the system. This information includes:
Die Name: Name of the die (if any) that is currently loaded in the machine.
Position: Position of the crimp head, relative to the die currently loaded.
Target Diameter: The crimp diameter target currently loaded into the machine.
This is the diameter the crimper will close to given the size of
the dies loaded into the machine.
Previous Max Max pressure on the last successful crimp.
Pressure:
Last Activity Sync: The last time that the machine has synced with CrimpCloud®.
Left Slide-Out Menu Functions
The left slide-out menu provides functions that can be executed from anywhere at any time:
Sync Activity: Sync Activity sends the latest crimper activity up to CrimpCloud®. Last Activity Sync data and time
described above detail the last successful data sync.
Change Die Mode: This mode allows the user to position the head to change dies. The machine tracks which dies are
loaded and will update information according to which dies are loaded.
"User Name" Change user function. This button displays the currently logged in user and provides a function to
login as a dierent user.
Main Menu: Return to the main menu of the application.
Crimper Return to the crimper operations menu.
Operations:
Technical Support: Bring up the technical support function.

13PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Using the Main Menu
Using the Main Menu
This screen provides the main functions of the crimper.
CrimpIQ™ Controller Main Menu Screen Options
Begin Crimping: This button brings up the functions to perform hydraulic and industrial hose crimping.
Favorites: The Favorites button provides users with direct access to favorited crimp speciications.
Setting and This button brings up all of the support, information, training manuals and coniguration options
Support: available for this machine.

14 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Crimper Operations
Crimper Operations
Main Crimper Operations Screen
The crimper operations screen is the starting point for setting up a crimping operation.
Load Crimp Speciications
This function allows the user to retrieve and load a crimp speciication from MyCrimp®.
Favorites: This function contains all of the crimp speciications that have been previously favorited.
Crimp to Diameter: This function allows the user to directly enter a crimp diameter. Once entered, the system
will recommend a die and allow the user to proceed to Crimp Operations.
MyCrimp® Industrial: This brings up an Industrial Crimp Calculator. This calculator can determine the crimper
setup based on the hose diameter or hose wall thickness.

15PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
MyCrimp® – Search Screen
Use the Hose Type, Coupling Type and Hose Size to ind the crimp speciications you need.
Key Functions of MyCrimp®
Hose Type: Drill down into a list of hose types.
Coupling Type: Drill down into a list of coupling types.
Hose Size: Drill down into the list of hose sizes.
Crimper: This is preset to the current crimper type and cannot be changed.
Favorite: Allows the user to favorite selections and view them at the top of the list.
Clear: The clear button and trash can icon clear previous selections and let the user
begin a new search.
Total Crimp Specs: Lists the total number of crimp speciications found that match the search criteria.
View Crimp Allows the user to view a list of matching crimp speciications.
Speciications:
Return to controller: Allows the user to abort the MyCrimp® search and return to the controller.
Crimper Operations

16 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Once you ind the desired crimp speciication, View Crimp Speciications will allow users to review the matching
crimp speciications.
MyCrimp® – Results Screen
This view provides a review of the hose and itting selected. Select “Begin Crimping” to begin crimping.
Crimper Operations

17PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
From the detailed view, users can view the full details of the crimp speciications.
Users can return to the previous screen with the Back button in the upper left corner or by using the "More Options" menu
in the upper right to “Export Speciication.” An Export Speciication button is also found below the speciication details.
MyCrimp® – Crimp This Speciication
Selecting “Crimp This Speciication” will allow the user to conirm the crimp speciication details.
Managing Crimp Speciications
Begin Crimping: Select this option to have the controller conigure the crimper and allow the operation to load/
conirm the correct die is loaded.
Die Options: In special situations, the user may wish to use an alternative die. To accomplish this, select the
Die Options button to bring up a list of all dies conigured for this machine.
Crimper Operations

18 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Crimp Speciications with Special Handling Requirements
There are cases where the user has to perform additional steps in order to select the correct crimp speciication for the
hose and itting combination. In these cases, MyCrimp® will prompt the user with additional information. Users can
then take the appropriate actions.
Crimper Operations

19PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Favoriting Crimp Speciications
Favoriting Crimp Speciications
The user can save frequently crimped speciications for easy access and repeated crimping.
This brings up a list of all the favorites saved on this machine. This scrollable list can be sorted by date added (Recent),
Favorite name (Name) or hose size.

20 PC440i Crimper – Operator Manual
PC440i Crimper with CrimpIQ™ Controller
Favoriting Crimp Speciications
Editing a Favorite
Users have the option to edit the Favorite name and notes. You also have the option to delete favorites
that are no longer needed.
Favorite Special Handling
There are a subset of crimp speciications that require special handling. For these favorites, users must make an additional
check to verify that the correct crimp speciication has been selected. The system will automatically bring up a
“User Action Required” dialog and ask the user for an additional conirmation (or cancel).
Note: For these speciications, the edit function does not allow the note to be changed.