CustomCrimp CC1000 User manual

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CC1000 CRIMPER OPERATORS MANUAL
WITH ACTTM CONTROLLER

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COMPONENT PARTS IDENTIFICATION -------------------------------------------------------------3
SPECIFICATIONS AND INITIAL SET UP -------------------------------------------------------------4
ACTTM CONTROL OPERATION -------------------------------------------------------------------------5
DIE SET UP AND INSTALLATION --------------------------------------------------------------------13
INITIAL SET UP AND MAINTENANCE --------------------------------------------------------------14
TROUBLESHOOTING ------------------------------------------------------------------------------------15
EXPLODEDPARTS BREAKDOWN ------------------------------------------------------------------------16
SAFETY PRECAUTIONS
READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS
BEFORE USING CRIMPER
KEEP HANDS AWAY FROM PINCH POINTS
CONSULT HOSE AND FITTING MANUFACTURER’S
SPECIFICATIONS FOR CORRECT MACHINE SETTINGS AND
CRIMP MEASUREMENTS
ALWAYS WEAR EYE PROTECTION
CC1000 Crimper Operators Manual With ACT™ Controller (Revised 03/28/2016)
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
[phone]

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Oil Level
Sight Glass
Power Switch
COMPONENT PART IDENTIFICATION
Master Dies
145mm to 99mm
Adapter Dies
99mm Hydraulic Dies
Hydraulic Power Unit
and Controls
145mm to 99mm
Adapter Die
Hydraulic Die
230mm to 145mm
Adapter Die
Master Die
230mm to 145mm
Adapter Dies
Return
Hose
Adjustable Mirror
Hydraulic 99mm Die
Storage Pockets
Industrial Die
Storage Shelves
Pressure
Hose

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CRIMPER SPECIFICATIONS AND INITIAL SET UP
SPECIFICATIONS:
MAX HEAD OPENING W/O DIES ------------------------------------------------------------------------350 MM (13.7 IN)
MASTER DIE INSIDE DIAMETER -------------------------------------------------------------------------230 MM (9.1 IN)
MAXIMUM DIE OPENING ----------------------------------------------------------DIE CLOSED DIAMETER + 125 MM
CRIMPER SIZE -----------------------------------------------------------------44 IN WIDE X 30 IN DEEP X 74 IN HIGH
WEIGHT ------------------------------------------------------------------------------------------------------6185 LB. (2904 KG)
ELECTRICAL REQUIREMENTS ----------------------------------------------------220 VOLT 3 PHASE (STANDARD)
--------------------------------------------------- 440 VOLT 3 PHASE (OPTIONAL)
MOTOR -------------------------------------------------------------------------------------------------7.5 HP (2 STAGE PUMP)
RESERVOIR CAPACITY --------------------------------------------------------------------------------------------50 US GAL
OIL TYPE ----------------------------------------------------------------------------------------------ISO 46 HYDRAULIC OIL
ADAPTER DIES ----------------------------------------------------------230 MM TO 145 MM AND 145 MM TO 99 MM
HOSE CAPACITY ----------------------------------------------------------------------------------------2-1/2 INCH 6 SPIRAL
--------------------------------------------------------------------------------------10 INCH INDUSTRIAL
INITIAL CRIMPER SET UP
• CHECK RESERVOIR OIL LEVELWITH SIGHT GLASS ON THE FRONT OF THE POWER UNIT.
• CHECK ELECTRICAL CIRCUIT TO BE CERTAIN THAT IT MATCHES THE CRIMPER REQUIREMENTS
AS SHOWN ON THE TAG ATTACHED TO THE CRIMPER CORD.
• MAKE CERTAIN THAT MOTOR ROTATES IN THE DIRECTION OF THE ARROW SHOWN ON THE
MOTOR HOUSING.
• IF MOTOR ROTATION IS INCORRECT REVERSE ANY TWO HOT WIRES IN THE CRIMPER PLUG.
• CONNECT THE PRESSURE AND RETURN HOSES AS SHOWN AND CONNECT THE YELLOW
ELECTRICAL CORD TO THE CONTROL PANEL.
• ALSO SEE ADDITIONAL INFORMATION ON THE INITIAL SET UPAND MAINTENANCE PAGE.

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AccuCrimp ACTTM CONTROL PANEL
EMERGENCY
STOP
MANUAL MODE FUNCTION: CLOSE DIES
AUTO MODE FUNCTION: CYCLE START
MANUAL MODE FUNCTION: OPEN DIES
AUTO MODE FUNCTION: CYCLE STOP
TOUCH SCREEN CONTROL PANEL
U.S. Patent No: 7,383,709
NOTE:
IF THE CRIMPER IS IN MANUAL MODE, THE
GREEN OPEN/CLOSE BUTTONS WILL OPEN AND
CLOSE THE CRIMPER HEAD.
IF THE CRIMPER IS IN AUTO MODE, THE BUT-
TONS FUNCTION AS CYCLE START AND CYCLE
STOP BUTTONS.
IF THE CRIMPER IS IN SEMI-AUTO MODE,
PRESSING THE FOOT SWITCH OR THE CLOSE
BUTTON WILL CLOSE THE CRIMPER HEAD AND
RELEASING WILL HALT THE CLOSING ACTION.

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ACTTM CONTROLLER QUICK START
While the ACTTM crimper has the ability to perform a
number of fully automatic functions, manual operation is
also possible. To make a manual crimp, two numbers are
needed:
• The closed diameter of the die (in either in or mm)
• The fi nished crimp diameter (in either in or mm)
That’s all you need to know. ACTTM does the rest.
TO MAKE A MANUAL CRIMP:
• Press START MOTOR.
• Select CRIMP TO DIAMETER.
• Enter the closed diameter of the die set in either in or mm and press ENTER.
Note: for a 25mm die, enter 2500. ACTTM will add 2 decmal places.
for a 1.5 inch die, enter 1500, ACTTM will add 3 decimal places.
• Enter the finished crimp diameter and press ENTER.
• From the ENTER CRIMP screen, press the MANUAL button to put the crimper in manual mode.
• Confirm that the die and finished crimp diameters are correct and that MANUAL MODE is displayed.
• Press and hold the green close button until the crimper stops closing.
• Check the final crimp diameter. If a minor correction is required see HOW TO MAKE MINOR
CORRECTIONS.
Tip: Pressing the CHANGE DIES button allows the crimper head to be fully opened or closed with
the green OPEN-CLOSE buttons on the controller front panel When the CHANGE DIES button is
blinking the dies can be opened and closed manually without altering any of the crimper settings.

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HOW TO MAKE MINOR CORRECTIONS
Due to variations in hose and fitting tolerances a minor crimp
adjustment may be required if the measured diameter of the final
crimp is not within the hose and fitting manufacturer’s specifications.
ACTTM technology makes minor corrections a simple process which
requires no addition or subtraction.
If the finished crimp diameter is not within the required
specifications:
• Press the ADJUST CRIMP button.
• Enter the measured diameter of the fitting in either inches or
mm (Do not enter the amount of correction)and press
ENTER
• Press SAVE.
• Make another crimp and verify that the fitting is within
specifications.
EXAMPLE: If the hose and fitting manufacturer specifies
that the finished crimp should measure 1.500 to 1.520 and
the measured crimp diameter was 1.530, simply enter the
measured diameter (1530 - Controller will supply 3 decimal
places) and press SAVE. The finished crimp diameter
can be entered in either in or mm and ACTTM will make the
conversion.
While a single correction will usually bring the hose and fitting
into specifications, the process can be repeated as many times as is
required.

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HOW TO ADD A SAVED DIE
Up to 50 different dies can be saved in the computer memory. These
dies can be recalled in the set up process eliminating the need to re-
enter the die size each time.
To enter a saved die:
• From the OPTION screen, press SETUP MODE.
• Select SAVED DIES.
• Select the save position (1-50) where the die is to be saved and
press the EDIT button.
• Enter a die description (up to 12 alpha/numeric characters).
• Enter diameter units (inch or metric).
• Enter the closed diameter of the die.
• Press SAVE and EXIT.
The saved die will now appear on the SELECTED DIE
screen. From this screen individual dies can be cleared or edited.
HOW TO RECALL A SAVED DIE
• Select CRIMP TO DIAMETER, and from the OPTION screen,
select USE SAVED DIE.
• Select the saved die (1-50) and press LOAD and then OK.
The die parameters will now be used for the crimp process.
• From the ENTER CRIMP screen press MANUAL.
• The saved die will now be shown on the crimp parameters
screen.

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HOW TO ADD A SAVED CRIMP
• Adjust the die diameter and crimp diameter as required and
place the crimper in MANUAL mode.
• Press SAVE.
• Select a location (1-150) and press EDIT.
• Enter a description (up to 12 characters).
• Press SAVE and EXIT.
The die and crimp setting can now be recalled from the
saved location as required.
TO RECALL SAVED CRIMP
• Select USE SAVED CRIMP from the option screen.
• Select a previously saved crimp from location 1-150.
• Press LOAD.
The saved crimp will appear on the manual screen.

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FULL AUTO MODE
With the crimper in FULL AUTO mode additional functions are
available:
• The crimper will cycle automatically from the CRIMP button on
the touch screen, the green CYCLE START button on the panel,
or the foot switch.
• To set the position to which the dies will retract, close the
crimper to the desired retract position prior to pressing the
FULL AUTO button.
• Pressing the FULL AUTO button will toggle the crimper into
SEMI-AUTO mode. In SEMI-AUTO mode, pressing the
FOOT SWITCH or the CLOSE button will close the crimper
head and releasing it will cause the head to stop closing. This
mode allows the crimper to be jogged into position allowing
more precise positioning of a fitting in the dies. Pressing the
SEMI AUTO button will toggle the crimper back to FULL
AUTO mode.
In FULL AUTO mode pressing the foot switch will start the crimp
cycle and the dies will stop closing when the crimp cycle is complete
• The COUNT function is activated allowing the operator to
monitor the number of crimps made.
• A measurement can be required after a preset number of
crimps. See SET REQUIRED MEASUREMENT.
SET REQUIRED MEASUREMENT
• Press the PRODUCTION button.
• Determine if 1 or 2 crimps will count as a crimp.
• Toggle the CRIMP ADJUSTMENT REMINDER to ON.
• Set the COUNTS BETWEEN CRIMP MEASUREMENTS
to the desired number and press OK.
• At the set interval, the ADJUST CRIMP screen will come up
and the operator will be asked to measure the last crimp and
enter a correction if required.