CustomCrimp PLC Series User manual

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Innovating SMART Hose Assembly Solutions Since 1979
ELECTRONIC “PLC” SERIES TEST BENCH
OPERATORS MANUAL
Updated 02/09/2018
Intuitive Screens: Lead the operator through the set up and monitoring of the test procedure.

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Innovating SMART Hose Assembly Solutions Since 1979
SAFETY PRECAUTIONS
! !
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE OPERATING BENCH.
• TEST BENCH PRODUCES EXTREMELY HIGH PRESSURE. USE CAUTION WHEN OPERATING.
• KEEP BOTH HANDS AWAY FROM PINCH POINTS.
• CONSULT HOSE AND FITTING MANUFACTURER’S SPECIFICATIONS FOR CORRECT TESTING
PROCEDURE.
• ALWAYS WEAR EYE PROTECTION.
SAFETY PRECAUTIONS

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SAFETY PRECAUTIONS------------------------------------------------------------------------------------------------------------------2
COMPONENT PARTS-------------------------------------------------------------------------------------------------------------------------------4
TECHNICAL DATA---------------------------------------------------------------------------------------------------------------5
FEATURES-----------------------------------------------------------------------------------------------------------------6
TEST BENCH CONNECTIONS / OPERATION-----------------------------------------------------------------------------------------------7
TEST PROCEDURE------------------------------------------------------------------------------------------------------------9
DATA LOG OPTION------------------------------------------------------------------------------------------------------------10
INFORMATIONAL TEST SCREENS-------------------------------------------------------------------------------------------------11
ADJUST THE PRESSURE RELEASE VALVE DIAGRAM-------------------------------------------------------------------------------12
ADJUST THE PRESSURE RELEASE VALVE PROCEDURE--------------------------------------------------------------------------13
PLC RESET / RELAY REPLACEMENT-------------------------------------------------------------------------------------------------------15
REPLACEMENT PARTS----------------------------------------------------------------------------------------------------16
CUSTOMCRIMP®“NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------18
CUSTOMCRIMP®CONTACT INFORMATION--------------------------------------------------------------------------------------19
TABLE OF CONTENT

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS IDENTIFICATION
Light Switch
Emergency Stop
USB Port
Printer
Stylus Pen
Test Receipt
Water Pressure Gage
Air Pressure Gage
6" Touch Screen
Air Drive
Regulator / Throttle
6 Port Multiple Outlet Manifold
Regulated Air Inlet
(Filter / Lubricator)
set at 80-90 psi
Removable
side panel
Door Handle
Electrical Enclosure
Built-in Work Light
Safety Switch
Door Lock
Note: Pump air throttle return
to “zero” psi after each test.
Regulated Air Inlet
(Filter / Lubricator)
Storage Drawer to keep frequently used tools and your
test bench accessories readily available.
CONTROL PANEL
Available Extension Trough

39"
78"
85"
67"
33"
17"
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Innovating SMART Hose Assembly Solutions Since 1979
TECHNICAL DATA

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Innovating SMART Hose Assembly Solutions Since 1979
FEATURES
Available extension trough in 10
foot sections.
Multi-Port Manifold Outlet, allows
multiple hose assemblies to be
tested at the same time.
Removable side panel permits the
testing of longer hose assemblies
with the attachment of an optional
trough.
Large capacity cabinet and fork
truck accessible chamber make
testing large hoses easy.
6" touch screen and user friendly
navigation. Intuitive Screens lead
the operator through the setup and
test execution process.
Results of each test are recorded
and can be printed on the included
printer or saved via USB port.

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Innovating SMART Hose Assembly Solutions Since 1979
TEST BENCH CONNECTIONS:
• Connect a water source (standard garden hose connection) to the water inlet connection located at the
rear of the control cabinet.
Note: Water supply pressure should not exceed 100 psi. If a water pressure booster pump is on the tester,
the water pressure should not exceed 50 psi. Damage to the booster pump can occur and can lead to water
leaks that can be fairly signicant.
• Connect a water drain hose (standard garden hose connection or barbed tting) to the water drain
connection located at the rear of the test cabinet. Run the drain to an appropriate drainage area.
• Connect an air supply of no more than 90 psi to the air inlet. Make sure the air lubricator is lled with oil.
This must be checked periodically to assure proper operation of the pump.
(Drip rate: 1 drip per 20 pump cycles).
Note: Air pressure greater than 90 psi can damage vital equipment on the tester.
• Plug in electrical cord to a standard 15 amp 110VAC outlet.
TEST BENCH OPERATIONS:
• Prior to operating the bench, make sure that the pressure regulator (throttle) knob is adjusted all the way
out (counterclockwise). The air pressure gauge on the front of the control cabinet should read 0 psi.
• Follow the screen prompts to input the desired test parameters.
• Raise the tank lid and connect hose to the tested to the manifold block.
Note: The manifold block standardly has 6 useable ports, 4 on the main face and 2 along the top. The ports
are standard with either HF4 (High Pressure) or LM9 (Medium-Low Pressure) connections. These are cone
and seat style connections.
• Secure any unused ports with the supplied plugs.
• Bleed the hose of air. Use the Fill Hose feature to ll the hose with water (or whatever uid media is
being used).
Note: This “Fill Hose” feature can be found on the Review Parameters screen, refer to test procedure
page.
TEST BENCH CONNECTIONS / OPERATION

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Innovating SMART Hose Assembly Solutions Since 1979
• While bleeding the hose, hold the opposite end of the hose higher than the manifold block. This forces
the air out the end of the hose.
• Once a steady stream of water is exiting the end of the hose, either cap the end of the hose o󰀨 or use
the needle valve included to close the end of the hose.
• Place the supplied rubber mat over the hose(s). This will help contain the hose and ends if a hose failure
occurs.
• Lower the tank lid and make sure the latch engages to ensure it is fully closed.
• Begin the test.
• Begin raising the air pressure regulator (Air Drive Throttle) until the desired test pressure has been
achieved.
Note: The high pressure pump is driven by air pressure. As the air pressure is increased using the regula-
tor (throttle), the water pressure will increase. The more air pressure supplied, the higher the test pressure.
• When the test cycle is complete, check over the test result page and print the test receipt if desired.
Note: Once the test result page has been passed, a test receipt can no longer be printed.
• Open the cabinet lid and remove the hose(s).
TEST BENCH CONNECTIONS / OPERATION

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Innovating SMART Hose Assembly Solutions Since 1979
TEST PROCEDURE
After the system initializes and
loads, the “Begin Test” screen
will appear.
Press New Test to initiate a test
or Repeat Test to repeat the
previous test.
Press the pressure button to
bring up the pressure adjust-
ment keypad screen.
Enter the max test pressure.
Keypads will pop up for set-
tings not indicated by arrows as
shown on the next screen.
Set the time for the hose to be
held at test pressure.
Enter the minimum pressure
allowed during the test cycle.
Enter the number of times that
the test is to be run.
Enter the delay time between
test cycles.
Review test parameters prior to
running test.
If test parameters and test
setup is correct, start test.
Test progress is shown. Test results are shown and the
print option is available.

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Innovating SMART Hose Assembly Solutions Since 1979
DATA LOG OPTION
From the main screen, select
Options.
Select More from the Options
menu.
Select Data Log from the
second Options screen.
Following instructions on the
screen, Install Flash Drive.
Press Start Transfer once the
unit is ready. (Screen will ash
briey)
Select Remove USB once
transfer completes. Exit and
remove Flash Drive from control
panel.
Log les will be saved on USB drive. Using a computer, locate the
EA_LogCopy folder to view data. A separate le will be saved and
labeled for each day. Information is most compatible with a program
like Microsoft Excel. Test results will be stored and formatted as
shown above.

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Innovating SMART Hose Assembly Solutions Since 1979
INFORMATIONAL TEST SCREENS
There are informational, adjustment and warning screens programmed into the software. While most are self
explanatory, a brief description is given below.
If the test does not complete
satisfactorily, the Hose Failed
screen will appear.
This screen details the cause of
the failed test.
Test cycle was unable to nish
due to pressure leaks.
Emergency stop is depressed. Test bench lid is not properly
closed and latched.
From the Main Menu Options
screen, default parameters can
be set.
Access to the memory table and
adjustments to the print tape
can be found here.

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Innovating SMART Hose Assembly Solutions Since 1979
ADJUST THE PRESSURE RELEASE VALVE
(Refer as Hipco Valve)
WEEP HOLE.
IF PACKING IS NOT
TIGHT ENOUGH, WATER
WILL COME OUT THIS HOLE.
ADJUSTMENT NUT
LOCK NUT
ADJUSTING THE PRESSURE
RELEASE VALVE
THE OBJECTIVE IS TO TIGHTEN
THE ADJUSTMENT NUT SO THAT
THE PACKING SEALS AROUND THE
NEEDLE AND STILL ALLOWS THE BLUE
DIAPHRAM TO MOVE THE NEEDLE
BACK AND FORTH TO BUILD
PRESSURE AND DRAIN.
1.) LOOSEN LOCK NUT
2.) SPIN THE BLUE DIAPHRAM OUT COUNTER
CLOCKWISE USING A WRENCH AND THE
ADJUSTMENT NUT SO IT SPINS FREELY.
3.) SPIN THE BLUE
DIAPHRAM CLOCKWISE
UNTIL YOU CAN FEEL THE PACKING MAKE
CONTACT WITH THE VALVE CONE.
4.) DO NOT TIGHTEN PAST THIS POINT.
DAMAGE TO STEM AND PACKING CAN OCCUR.
TIGHTENING PAST THIS POINT WILL BEGIN TO
COMPRESS THE PACKING AND WILL ALSO
MAKE THE STEM STICK AGAIN.
5.) TIGHTEN THE LOCK NUT AND TEST OUT THE
UNIT TO CHECK THE ADJUSTMENT.
ADJUSTMENT INSTRUCTIONS
ADJUSTING THE PRESSURE RELEASE VALVE
• Follow the instructions on page 13-14.

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Innovating SMART Hose Assembly Solutions Since 1979
ADJUST THE PRESSURE RELEASE VALVE
1). Disconnect the Air Line.
2). Use a 1" wrench to grab the Adjustment Nut and with a 1-⅛ "
wrench to loosen the Lock Nut, until spins freely.
(Adjustment Nut will be closest to Blue Diaphragm).
3). Rotate the Blue Diaphragm counter-clockwise to remove it from
the Block.
4). Clean the Blue Diaphragm Needle and apply grease.
Remove the Packing from the block and clean them.
Place the Packing on the Blue Diaphragm Needle.

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Innovating SMART Hose Assembly Solutions Since 1979
ADJUST THE PRESSURE RELEASE VALVE
5). The Packing must follow the order as shown.
Apply grease all over the packing.
6). Place the Blue Diaphragm Needle (Packing installed)
into the Block and rotate the Blue Diaphragm clockwise
until you can feel the packing (Seals) make contact with
the valve cone.
Note: Do not tighten past this point, damage to stem
and packing can occur. Tightening past this point will
begin to compress the packing and will also make the
stem stick again.
7). Use a 1 inch wrench to grab the Adjustment Nut and
with a 1-⅛" wrench to tighten the Lock Nut. (Just snug tight).
8). Reinstall in machine to check operation.
• Best to plug o󰀨 manifold and test to a pressure.
• If water comes out of weeping hole than go back to
step 6 and snug stem slightly more.
Note: The objective is to tighten the Adjustment Nut so
that the packing seals around the needle and still allows
the Blue Diaphragm to move the needle back and forth
to build pressure and drain.

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Innovating SMART Hose Assembly Solutions Since 1979
PLC RESET / RELAY REPLACEMENT
The PLC (Programmable Logic Controller) requires a relatively constant source of electrical power.
Power surges, outages or drops in power can cause the PLC to lose its settings.
This may result in missing or misplaced information on the controller screen.
Resetting the PLC to its original settings is a simple procedure:
• Open the electrical enclosure.
• Power up the electronic test bench from the main power switch. The test bench must be powered on
during the PLC reset procedure.
• Move the three position toggle switch on top of the PLC right to the STOP position and then left to the
RUN position.
• Return the toggle switch to the center TERM position.
• Cycle the main power o󰀨 and back on.
• The PLC and the electronic test bench should now operate normally.
• Close the electrical enclosure.
Relay Replacement:
• There are 3 relays which control the Water Inlet, (HIPCO) Dump Valve, and Pump Valve functions of
the electronic test bench. If one of these functions is inoperable these relays can be replaced.
• All 3 relays are identical and interchangeable.
Water
Water
A1 Dump Valve
A1 Dump Valve A2 Pump Valve
A2 Pump Valve

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Innovating SMART Hose Assembly Solutions Since 1979
REPLACEMENT PARTS
⅜" NPT P/N:103687-06¼" NPT P/N:103687-04
RELIEF VALVE P/N:104241
¾" NPT P/N:103687-12 ½" JIC P/N:104428-08
5000 PSI RELIEF VALVE P/N:104642
½" NPT P/N:103687-08
⅜" JIC P/N:104428-06
2WAY NEEDLE VALVE P/N:104352
REPAIR SEALS P/N:104241-SEALS HIPCO 60K AIR VALVE REPAIR KIT
P/N:104241-KIT

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Innovating SMART Hose Assembly Solutions Since 1979
REPLACEMENT PARTS
MANIFOLD BLOCK P/N:102100AIR REGULATOR P/N:104115
BE 3500 PUMP P/N:103862BE 2500 PUMP P/N:103861
BE 1500 PUMP P/N:103860

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Innovating SMART Hose Assembly Solutions Since 1979
All Custom Crimp® Products are warranted to be free of defects in workmanship and materials for one
year from the date of installation. This warranty ends when the product becomes unusable for reasons
other than defects in workmanship or material.
Any Custom Crimp® Product proven to be defective in workmanship or material will be repaired or replaced
at no charge. To obtain benets of this warranty, rst, contact Warranty Repair Department at Custom
Machining Services at [phone] and then deliver via prepaid transportation the complete hydraulic
product to:
ATTN: WARRANTY REPAIR DEPT.
Custom Machining Services, Inc.
318 North Co. Rd 400 East
Valparaiso IN 46383
If any product or part manufactured by Custom Crimp® is found to be defective by Custom Crimp®, at
its option, Custom Crimp® will either repair or replace the defective part or product and return via ground
transportation, freight prepaid.
Custom Crimp® will not cover any incoming or outgoing freight charges for machines sold outside
The United States.
This warranty does not cover any product or part which is worn out, abused, altered, used for a purpose
other than for which it was intended, or used in a manner which was inconsistent with any instructions
regarding its use.
Electric motors are separately warranted by their manufacturer under the conditions stated in their separate
warranty.
Custom Crimp® “No-Nonsense” Warranty Statement
CUSTOM CRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.

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Innovating SMART Hose Assembly Solutions Since 1979
For support: [email protected]For sales: [email protected]Visit us at: www.customcrimp.com
CUSTOM CRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.
CUSTOM CRIMP®|Custom Machining Services, Inc.
326 North 400 East Valparaiso, IN 46383
[phone]Custom Crimp®www.customcrimp.com
Innovating SMART Hose Assembly Solutions Since 1979