GLW MC 25 User manual

MC 25
Instruction for use
MC 25
Date of issue: 12/2009
Save this instruction for further use!

MC 25 CONTENTS
12/09
Safety................................................................
.........................
1 - 3
Basic information ................................................................................................
...
1
Symbols................................................................................................
.................
1
Danger of machine................................................................................................
.
1
Dedicated usage................................................................................................
....
2
Dangers................................................................................................
.................
2
Places for use................................................................................................
........
2
Safety devices ................................................................................................
.......
3
Authorized user................................................................................................
......
3
Warranty................................................................................................
................
3
Description................................................................
................
4 - 8
Extent of Delivery................................................................................................
...
4
Usage................................................................................................
....................
5
Standard components overview................................................................
.............
6
Standard components functions................................................................
.............
7
Commissioning................................................................
.........
9 - 11
Operation................................................................
...................
12 - 13
Retooling................................................................
...................
14 - 15
Faults................................................................
.........................
16
Trouble-shooting................................................................
......
17 - 23
Spare parts................................................................
................
24 - 25
Technical data................................................................
...........
26
Type plate................................................................................................
..............
26
EC Declaration of Conformity................................
..................
27

MC 25 SAFETY
12/09 1
Basic information
The basic condition for safe use and proper work of the mc 25 is the knowledge and attention of
the safety information.
Important for your safety!
The following safety information must be observed by all persons who will work with the mc 25.
All rules and instructions on the working place must be observed, especially those for prevention of
accidents.
Symbols
This instruction for use contains the following symbols:
marks a possible danger of injury and accident or a possible damage of the mc 25.
!marks using instructions.
Danger of machine
The mc 25 complies with the relevant safety standards and was subjected to a security check.
It provides safety equipment.
Danger can be caused in case of misuse for
life and limb of the user,
the machine.
The mc 25 must be used only
for dedicated usage and
in safe proper working condition.
All persons commissioning, maintaining and working with the mc 25 must be
qualified and
observe this manual for is correct use.

SAFETY MC 25
2 12/09
Dedicated usage
Use the mc 25 only for automatic stripping and crimping.
End sleeves with cross-sections ranging from 0.5 to 2.5 mm2and a strip length of 8 mm must be
used.
Only the intended PVC insulated cables may be inserted into the funnel guide of the mc 25. Never
insert solid metal parts or items. The stripping knifes would be damaged.
Third party reconstruction and changes of the mc 25 beyond retooling are not allowed because of
safety!
!
Observing of all information in compliance with the working conditions belong to the
dedicated application!
Dangers
Use the mc 25 only when the cover is closed.
Before carrying out any work at opened cover (e.g. retooling, maintenance work) disconnect the
mc 25 from the mains supply.
Make sure that no strange objects are inside the case.
Places for use
Avoid operation and keeping at
damp or dusty places,
places exposed to high or low temperatures or direct sunlight (Operating temperature range: 15
C to 35 C).
Condensation can form when moving from a cold to a warm place.
Open cover to evaporate condensation before using the mc 25.
Do not spill any liquids over the mc 25.
Protect the mc 25 from heavy vibrations and jolts.

MC 25 SAFETY
12/09 3
Safety devices
The mc 25 can be switched off through:
the mains switch (0 off),
pulling out the mains plug,
sliding back the cover (by two micro switches).
The cover is built in for safety. It may not be changed, removed or by-passed by reconstructions.
A label points to existing dangers.
Authorized user
Only authorized and instructed users are allowed to work with the mc 25.
The user has a responsibility to other persons inside the mc 25 working place.
The customer must
make the instruction for use accessible to the user and
assure that the user has read and understood it.
Warranty
In general our common terms of sale and delivery are valid.
These are available by the customer latest at conclusion of contract.
Warranty for damages to property and personal injury is impossible if violation against the following
points:
Not dedicated usage of the mc 25.
Improper places for use.
Improper use and use beyond those described in the manual for use.
Third party reconstruction of the mc 25.
Continued use of the mc 25 when faults are recognised.
Un-Authorised repairs.
!Only use original spare parts!

DESCRIPTION MC 25
4 12/09
Extent of Delivery
Diagram 1
Extent of delivery
1 MC 25 1 piece 5 Accessories box 1 piece
2 Mains cable 1 piece
Content:
3 Container for insulation scrap 1 piece 6 Feeder blocks for end sleeves 5 pieces
4 Instruction for use in German 1 piece 0.5 to 2.5 mm
2
and additionally one in the
specific language at foreign 7 Tool insert for 0.5 to 2.5 mm25 pieces
delivery 8 Locator (reserve) 5 pieces
9 Bolt, 6 mm in diameter 1 piece
!The parts 6, 7 and 8 have the same colour code as end sleeves complying with DIN.

MC 25 DESCRIPTION
12/09 5
Usage
The MC 25 is for fully automatic stripping of flexible PVC insulated cables and subsequent
pressing on of insulated end sleeves on reels.
It uses end sleeves complying with DIN 46228 Part 4 with cross-sections ranging from 0.5 to
2.5 mm2with a stripping length of 8 mm. Due to the short cycle times (1.5 s) and simple changing
of cross-sections (below 10 s) the mc 25 is not only suitable for use in workshops but also in
complex cable production systems.
The following end sleeves can be used by the mc 25:
End sleeves bands inside the dispenser
Cross-section
mm2length mm DIN colour code Packing unit pieces/roll Art.-No.
0.5 8 white 1000 A00555 K
0.75 8 grey 1000 A00755 K
1.0 8 red 1000 A01055 K
1.5 8 black 1000 A01555 K
2.5 8 blue 500 A02555 K

DESCRIPTION MC 25
6 12/09
Standard components overview
Diagram 2 Standard components
1 Grip 9 Mains connection
2 Funnel guide 10 Mains fuses
3 Counter 11 Mains switch
4 Reset button 12 Transformer fuses
5 Tool insert 13 Reverse button
6 Bolt 14 End-sleeve dispenser holder
7 Cover 15 Container
8 End-sleeve feeder

MC 25 DESCRIPTION
12/09 7
Standard components functions
1 Grip
For transport of the mc 25.
2 Funnel guide
The cable to be processed is inserted into the mc 25 through the funnel guide. Once it has been
inserted, work commences automatically.
3 Counter (000000 to 999999)
The counter counts the number of end-sleeves used.
The mc 25 performs automatically a reset to 0 at power-off.
4 Reset button
This button resets the counter to 0.
5 Tool insert (colour coded)
Positions the end sleeve and strips the cable.
The appropriate tool insert must be installed for every cross-section.
6 Bolt
Secures the tool insert.
7 Cover
Protects the user from moving parts inside the mc 25.
The mc 25 will only operate when the cover is properly closed.
8 End-sleeve feeder
The end-sleeve feeder positions the end sleeves. The appropriate end-sleeve feeder must be
installed for every cross-section.
9 Mains connection
The mains cable must be connected to the input connector.
10 Mains fuses
Two 0,63 A/T/250 V fine wire fuses integrated into the mains connection.
11 Mains switch
Switches the power supply to the mc 25 on (position I) or off (position 0).

DESCRIPTION MC 25
8 12/09
12 Transformer fuses
One 4.0 A/T/250 V fine wire fuse for secondary device.
13 Reverse button
Pressing this button puts the mc 25 in the maintenance position.
Pressing again will put the mc 25 in start position.
14 End-sleeve dispenser holder
Holds the end-sleeves reel dispenser.
15 Container
The container collects the insulation scrap. It must be emptied regularly.

MC 25 COMMISSIONING
12/09 9
1. Chose the installation site
The installation site of the mc 25 must be level and horizontal.
!Observe the working conditions in chapter safety, section places for use.
2. Prepare the dispenser
Open the dispenser and tear-off the strap at the
edge (1).
Pull out the end-sleeves band (2) approximately
20 cm.
3. Prepare the end-sleeve feeder
Take end-sleeve feeder with proper cross-
section from the accessories box.
!
Observe to the colour code of the end
-
sleeve feeder.
Insert the end sleeves (1) in the guide sideways
until the stop pin is reached.
Pull the pin (2) upwards, move the end sleeves
to the mark (3) and let the pin go.
!
Check that the pin has clicked properly
into place.
Diagram 3 Prepare the dispenser
Diagram 4 Prepare the end-sleeve feeder

COMMISSIONING MC 25
10 12/09
4. Fit the end-sleeve feeder
!
Verify that the tool insert is not
installed yet.
Slide the cover (1) back.
Insert the end-sleeve feeder (2) sideways and
place it on the bolts (3).
!Check that the end-sleeve feeder has
clicked properly into place.
5. Mount the dispenser
Mount the dispenser (1) on the holder.
!
Check that the dispenser has clicked
properly into place.
6. Mount the tool insert
Take the tool insert with proper cross-section
and bolt from the accessories box.
!
Observe to the colour code of the tool
insert.
Mount the tool insert (1) sideways.
Fit the bolt (2) into the hole until it stops.
Diagram 5 Fit the end-sleeve feeder
Diagram 6 Mount the dispenser
Diagram 7 Mount the tool insert

MC 25 COMMISSIONING
12/09 11
7. Place to operation mode
Put the dispenser (1) in operation mode.
Close the cover (2).
!
Be sure that the end
-
sleeves band is
fed properly.
Connect the mains cable with the appropriate
connectors (3,4) to the mc 25 and the mains
supply.
The mc 25 is now ready for operation.
Diagram 8 Place to operation mode

OPERATION MC 25
12 12/09
1. Prepare the cable
Before crimping cable must be aligned as
straight as possible.
2. Cut the cable
Cut the cable clean and straight.
!
Poor cut (Diagram 11) frequently
results in unsuccessful crimping.
3. Start the mc 25
Check that the cover (1) is closed.
Turn on (position I) the mc 25 with the mains
switch (2).
Check that counter (3) is at 0.
!
If the counter is not at 0 refer to
chapter faults.
Diagram 9 Prepare the cable
Diagram 10 Cutting cable
Diagram 11 Poor cut
Diagram 12 Start the mc 25

MC 25 OPERATION
12/09 13
4. Crimping cables
Insert the cable (1) straight into the funnel guide
until it stops.
Crimping and stripping works automatically.
Pull out the cable (2) straight when the mc 25
has stopped.
!
Refer to chapter faults when operating
faults or unsuccessful crimping
occurs.
Read counter (3) if required and set it to 0 with
the reset button (4).
5. Stop operation
Read counter (1) if required.
Turn off (position 0) the mc 25 with the mains
switch (2).
6. Daily maintenance
Disconnect the mains supply from the
mc 25 and open cover.
Turn off (position 0) the mc 25 with mains
switch (1).
Disconnect mains cable (2).
Slide the cover (3) back.
Remove (4) insulation scraps inside the mc 25.
Pull out the container (5).
Dispose insulation scraps and insert container.
Close the cover (6).
Connect mains cable (7).
Diagram 13 Crimping cables
Diagram 14 Stop operation
Diagram 15 Daily maintenance

RETOOLING MC 25
14 12/09
1. Prepare the retooling
Disconnect the mains supply from the
mc 25 and open cover.
Read counter if required.
Turn off the mc 25 with mains switch (1).
Disconnect mains cable (2).
Slide back the cover (3).
Pull the pin (4) upwards and pull out the end
sleeves (5).
Remove the dispenser (6) and roll up the
remaining end sleeves.
Fold back the dispenser holder (7).
2. Remove the tool insert
Pull out the bolt (1).
The tool insert (2) must be removed sideways.
Put the tool insert and the bolt into the
accessories box.
Diagram 16 Prepare the retooling
Diagram 17 Remove the tool insert

MC 25 RETOOLING
12/09 15
3. Remove the end-sleeve feeder
Pull the end-sleeve feeder (1) towards the rear
and remove it sideways (2).
Put the end-sleeve feeder into the accessories
box.
Continue as described with step 2 to 7 in chapter commissioning.
Diagram 18 Remove the end-sleeve feeder

FAULTS MC 25
16 12/09
When operating faults occur trouble-shooting depends on different fault conditions.
After recognizing the fault condition trouble-shooting can be carried out by the following points.
Fault condition 1
Cable cannot be inserted.
Fault condition 2
Crimping has not been completed.
Fault condition 3
Crimping is completed.
Cable cannot be pulled out.
Fault condition 4
Cable insulation is not completely removed.
Fault condition 5
The end sleeve is not separated from band.
Fault condition 6
Counter respectively mc 25 do not work.
Fault condition 7
The mc 25 works too slow but counter works.
Fault condition 8
Crimp stamp or crimp forging die is defective.