HCL PT-CB-02 Instruction Manual

Hose Clamp Electro-
Pneumatic Control Unit
Operation, Parts & Safety Manual
Original Instructions

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Tooling
Index
Operation
1.1 Warning & Safety Instructions
1.2 Pneumatic Tool Conrol Unit
Touch Screen
2.1 Administrator
2.2 User
2.3 Set Up
2.4 Run, Warning and Advice
Reference
3.1 Control Unit Schematic
3.2 Control Unit Wiring Diagram
3.3 Control Unit Pneumatic Diagram
CE Marking
4.1 EC Declaration of Conformity
The control unit is designed to be used with the following pneumatic tools:
Piston Tool
Calliper Tool
Calliper Tool Dry Cycle
Ezyclik Calliper Tool
Ezyclik Caliper Tool Dry Cycle

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Read these instructions carefully:
ELECTRICAL
An Electrical supply represents a source of considerable potential energy. Precautions should be taken to prevent accidents.
– Electrical supplies must be disconnected before any adjustments, maintenance or dismantling.
– The Maximum allowable electrical supply should be observed.
COMPRESSED AIR
A compressed air supply represents a source of considerable potential energy. Precautions should be taken to prevent
accidents.
– Maximum operating pressure – 9.9 Bar
– Recommendedairowintounit–>50L/min.
Note.Iftheairowisnotachievablealongertimedelaymayneedtobesettoallowthejawsorpistontoclosefully.
– Usea50micronlterorbetter.
– Input air must be non-lubricated.
– Compressed air should never impinge in the body.
– Ports and pipes etc. should never be blocked by hand.
– Beforeconnectinganypneumaticequipmenttoacompressedairsupply,mountings,ttings,pipeworkandelectrical
connections should be checked for security, and all or any protective transit plugs removed.
– Nopipeworkalterationsorremovalofttingsshouldbeattemptedwithairsuppliesconnected
– Compressed air supplies must be disconnected before any adjustments, maintenance or dismantling.
– The maximum allowable operating pressures should be observed.
TRAINING
The control unit must not be used by persons not properly trained in its use. Be certain that you receive proper training from
youremployer.IfyouhaveanyquestionscontactyourHCLrepresentative.
WEIGHT
Control Unit – 6.7Kg
NOISE
– Soundpressurelevelislessthan70dB
– Vibrationlevelislessthan2.5ms-2
Operation - Warning & Safety Instructions
1.1

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Introduction
Developed exclusively for the range of Herbie Clip
and Ezyclik pneumatic tools, the Pneumatic Control
system gives a greater level of air pressure control.
Features
In the drive to eliminate error from production lines the
control system has a number of features including:
HMI touch screen control
Digital control of air pressure – to maintain a
consistent tightening force
Digital control of clamping time – to maintain a
consistent tightening time
Dry cycle detection (tool option) – Detects tool use
without a clip being in place
In process advisory information screens
Batch and unit count control
Supervisory control
Adjustable orientation of the HMI screen
External Signal Output
A 24v output signal can be supplied to the production
line once the prescribed number of clamps has been
tightened.
Low Maintenance
TheControlUnithasnospecicmaintenance
scheduleandHCLFastenersprovidefullbackupand
servicing support.
1 or 2-Preset Program Options
The Control Unit program allows the user to save the
following process parameters within the Set Up pages:
– Clamp Time
– Tool Pressure
– Clamp Count (number of clamps per production
assembly)
– Batch Count (number of production assemblies in
batch)
If required, the Control Unit can also be set up with the
ability to save 2 different sets of
process parameters.
Operation - Pneumatic Tool Control Unit
1.2

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Start Up
Connect the Control Box to electrical and
compressed air supplies. Connect the tool to the
Control box. In both cases refer to the images
shown in the ‘Pneumatic Tool Control unit’ section
of this manual
Switch on the power to the control box
The ‘Start Up’ screen is displayed
This will switch to the Main screen automatically
after a short time but can be switched manually by
touching the screen during this period
Language
TheLanguagerequiredcanbechosenbyselecting
theagonthestartscreen
Select the required language
Select ‘Back’ to return to the Start screen
➜
➜
➜ ➜
AdministratorLogin
IntheStartscreenselect‘Login’
The‘UserLogin’Screenisdisplayed
The control box is supplied with a default
Administrator level login
Fromthe‘User’dropdownmenuselect‘Admin’
Enter default password 1234
Select‘Login’
Note.Forsecurityreasonsitisadvisedthatthe
default User ‘Admin’ is deleted once administrative
users have been set up on the control box
‘Command succcessful’ message is displayed
withinthe‘UserLogin’screen
If incorrect login details entered ‘Command
Unsuccessful’ message is displayed
➜ ➜
Touch Screen - Administrator
2.1

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Create New User
In the ‘Admin’ screen select ‘Create New User’
– OR – ‘Back’ To return to the previous screen
In the ‘Admin – New User’ screen enter the name of
thenewuserinthe‘Name’eld
Enter the new users password in the ‘Password’
eld
Decide if the new user is a ‘User’ or if they also have
‘Admin’ authority
Selecteitherthe‘User’or‘Admin’elds
Note. When selecting ‘Admin’ both the ‘Admin’ and
‘User’eldsarehighlighted
Whenselecting‘User’onlythe‘User’eldis
highlighted
Select ‘Create’ – OR – Back’ To return to the
previous screen
In the ‘Admin’ screen the ‘Command Successful’
message is displayed
Select ‘Back’ To return to the previous screen
➜ ➜
➜ ➜
➜
AdministratorLogin(cont)
Start screen opens with the addition of an ‘Admin’
button
Administrator Actions
LoginasanAdministratorviathefrontscreen.See
AdministratorLoginsection
When logged in as an Administrator the front screen
has the option of the ‘ADMIN’ button.
Select ‘Admin’
The ‘Admin’ screen is displayed
To return to the previous page select the ‘Back’
button
➜
Touch Screen - Administrator
2.1

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In the ‘Admin’ screen the ‘Command Successful’
message is displayed
Select ‘Back’ To return to the previous screen
Change User Password
In the ‘Admin’ screen select ‘Change User Password’
– OR – ‘Back’ To return to the previous screen
In the ‘Admin – Change User Password’ screen
enter the name of the user in the ‘Name’ drop down
menu
Enter the users new password in the ‘Password’
eld
Entertheusersnewpasswordinthe‘Conrm
Password’eld
➜ ➜ ➜
Delete User
In the ‘Admin’ screen select ‘Delete User’
To return to the previous page select the ‘Back’
button
In the ‘Admin – Delete User’ screen select the name
of the user to be deleted in the ‘Name’ drop down
menu
Select ‘Delete’ – OR – ‘Back’ To return to the
previous screen
Inthe‘Admin–DeleteUser’screenaconrmation
message is displayed
Select ‘OK or Cancel’ – OR – ‘Back’ To return to the
previous screen
➜ ➜ ➜
Touch Screen - Administrator
2.1

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UserLogin–EquipmentSwitchOn
Inthe‘Start’screenSelect‘Login’
The‘UserLogin’screenisdisplayed
Select the user form the ‘User’ drop down menu
Enter the associated password
Select‘Login’
‘Command Successful’ advice message displayed
on screen
If incorrect login details entered ‘Command
Unsuccessful’ message displayed on screen –
Select ‘Close’
Depending on the type of user logged in the Start
screen opens with either:
‘Change User’ and ‘Change Password’ or ‘Change
User’ and ‘Admin’ options
➜ ➜ ➜ ➜
Change User Password (cont)
Change Password box is displayed
Select ‘Change Password’ – OR – Back’ To return to
the previous screen
In the ‘Admin – Change Password’ screen a
conrmationmessageisdisplayed
‘PleaseConrmOperation’
Select ‘OK or Cancel’
In the ‘Admin – Change Password’ screen the
‘Command Successful’ message is displayed
Select ‘Back’ To return to the previous screen
➜ ➜ ➜
Touch Screen - User
2.2

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UserLogin–EquipmentSwitch
On (cont)
Change User
In Start screen Select ‘Change User’
The‘UserLogin’screenisdisplayed
SelectLogout
Select the user from the ‘User’ drop down menu
Enter the associated password
Select‘Login’
➜➜ ➜
‘Command Successful’ advice message displayed
on screen
If incorrect login details entered ‘Command
Unsuccessful’ message displayed on screen
The start screen is displayed after a short time
delay
Change Password
Select ‘Change Password’
➜ ➜ ➜
Touch Screen - User
2.2

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Inthe‘UserLogin’screenSelect‘Logout’
Inthe‘UserLogin’screenthe‘Command
Successful’ message is displayed
Select ‘Close’
The front screen is displayed
Set Up
In Start screen Select ‘Set Up’
➜ ➜ ➜ ➜
Change Password (cont)
The ‘Current User – Password Change’ screen is
displayed
Enter ‘Current Password’
Enter ‘New Password’
Enter‘ConrmPassword’
The‘ChangePassword’eldisdisplayed
Note.Ifthe‘ChangePassword’eldisnotdisplayed
there is an error with the information entered in the
passwordelds
Select ‘Change Password’ – OR – Select ‘Back’ to
return to the previous screen
The‘Pleaseconrmtheoperation’messageis
displayed
Select ‘OK’ or ‘Cancel’
Logout
In Start screen Select ‘Change User’
➜ ➜ ➜
Touch Screen - User / Set Up
2.3

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Set Up (cont)
The ‘Set Up – Select Program’ screen is displayed
Select program
Clamp Time
In the ‘Set-Up – Program #’ screen select ‘Set Clamp
Time’
The ‘Set-Up – Program # – Clamp Time’ screen is
displayed
Selectthe‘ClampTime’eld.Theon-screenkeypad
will be displayed
Enter the desired clamp time
Select ‘Run #’ to use equipment – OR – Select
‘Back’ to return to the previous screen
➜
Set Pressure
In the ‘Set-Up – Program #’ screen select ‘Set
Pressure’
The ‘Set-Up – Program # - Tool Pressure’ screen is
displayed
Select the ‘Unit Of Pressure’ type:
PSI , Bar or MPa
The‘SupplyPressure’eldisadvisoryandcannot
be set
Selectthe‘ToolPressure’eld.Theon-screen
keypad will be displayed
Enter the desired tool pressure
Select ‘Run #’ to use equipment – OR – Select
‘Back’ to return to the previous screen
Set Counters
In the ‘Set-Up – Program #’ screen select ‘Set
Counters’
➜
➜ ➜
➜ ➜
Touch Screen - Set Up
2.3

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Set Time & Date
In the ‘Set-Up – Program #’ screen select ‘Time &
Date’
In the ‘Set Time & Date’ screen
The‘CurrentTime/Date’–‘DD’/‘MM’/‘YYYY’and
‘hh’:‘mm’eldsareadvisoryandcannotbeset
Inthe‘NewTime/Date’theeldsfor‘DD’/‘MM’/
‘YYYY’and‘hh’:‘mm’canbeindividuallyselected.
Foreachselectiontheon-screenkeypadwillbe
displayed
Enterthedesiredgurefor‘DD’/‘MM’/‘YYYY’and
‘hh’ : ‘mm’
Select‘SetNewTime/Date’
The newly entered selections will become the
‘CurrentTime/Date’
Select ‘Back’ to return to the previous screen
➜ ➜
The ‘Set-Up – Program # - Counters’ screen is
displayed
Note.The‘ClampCount’and‘BatchCount’eldsare
advisory only and cannot be set
Selectthe‘ClampCountTotal’eld.Theon-screen
keypad will be displayed
Enter the desired ‘Clamp Count Total’ per batch
Repeatforthe‘BatchCountTotal’eld
The counters can be zeroed by selecting ‘Reset
Counters’
The‘DryCycles’eldisadvisoryandcannotbeset
but can be zeroed by selecting ‘Reset Dry Cycle’
Select ‘Run #’ to use equipment – OR – Select
‘Back’ to return to the previous screen
SetLogs
Inthe‘Set-Up–Program#’pageselect‘Log’
Inthe‘Set-Up–Program#–Logs’screen
The ‘Total Clamps’, ‘Total Batches’ and ‘Total Dry
Cycles’eldsareadvisoryandcannotbeset.They
canbezeroedbyselecting‘ResetAllLogs’
Select ‘Run #’ to use equipment – OR – Select
‘Back’ to return to the previous screen
➜ ➜ ➜
Touch Screen - Set Up
2.3

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If a ‘Dry Cycle is registered the indicator light
illuminates red
To accompany the red indicator light on the ‘Run –
Program #’ screen an on screen message box ‘Dry
Cycle’ is displayed
This Indicates that the tool has been operated but
hasnotttedaHoseClampunit
Message disappears on screen after completion of
the operation cycle
On completion of a good clamp cycle the ‘Clamp
Count/Totalindicatorlightwillbeilluminatedgreen
➜ ➜ ➜
Run
In the ‘Start’ screen select ‘Run
The ‘Run – Select Program’ screen is displayed
Select the program number required –OR – Select
‘Back’ to return to the previous screen
The ‘Run – Program #’ page is displayed
The‘ClampCount/Total’,‘BatchCount/Total’,‘Dry
Cycles’, ‘Clamp Time’, ‘Supply Pressure’ and ‘Tool
Pressure’eldsareadvisoryandcannotbeset
➜ ➜ ➜
Touch Screen - Run, Warning and Advice Screens
2.4

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Warning and Advice Screens
‘SupplyPressureTooLow’warning
Check supply pressure and adjust
Should a user try to access the ‘Set Up’ screens
without being logged in a warning message is
displayed ‘Password Protected – Access Denied’
Select‘Close’toreturntotheFrontscreen
➜ ➜
Run (cont)
Oncompletionofthe‘BatchTotal’the‘BatchCount/
Total indicator light will also be illuminated green
To accompany the ‘Batch Total’ green indicator light
an on screen message box ‘Batch Complete’ is
displayed
Select ‘Press To Clear’ to return to the previous page
The ‘Run - Program#’ screen is displayed with the
count totals reverting to zero
➜ ➜ ➜
Touch Screen - Run, Warning and Advice Screens
2.4

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Reference - Control Unit Schematic
SUPPLY
NFF
V1EX
SUPPLY
R1 EX
240vAC
AIR
AIR TO
TOOL
TOOL
159
250
300
Note. The orientation of the HMI unit is adjustable
by 90, 180 and 270 degrees. This is to allow the
control unit to be located in the most suitable
position for the operator and also for access to
services.
This feature requires the removal of the control
unit front cover to enable the HMI unit to be
repositioned.
Ensure that the Control Unit is turned off before
gaining access. Refer to the Warning & Safety
Instructions within this manual.
3.1

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A 2 A 1
F 1 - 5 A
NL
-V+ V
P S U
3 5 W 2 4 V dc
- F 2
1 A (T )
0 - 5 Vdc
PSE5 4 0 - R 0 6
BLU
BLK
B R N
C O M3
0 V
G N D
24V
W ein te k MT 8 0 5 0 iE
0 V
0 V
AO 1 -V
AO 0 -V
O u t p u t
A n a lo g u e
T MC 2 A Q2 V
- F 3
0 . 5 A(T )
IT V 1 0 5 0 -3 1 2 C N 4
(0 .0 0 6 - 0 .9 9 M Pa )
0 - 1 0 V d c
B R N
BLU
W H I
BLK
1 4A 2
A 1 1 3 +
I0
Q 0 Q 1 V-Q 3 Q 5 V +Q 40 V
0 V
I1 I8
A I0
PE
0 V
I5
Q 6Q 2
I2 I4
24V
S E R I A L
I6
A I1
C O M I3 I7
S chneid er M2 2 1 - T M2 2 1 C 1 6 T
1 4A 2
A 1 1 3 +
85-230VAC
3
1 2
1 - 4 Tr ig g e r
0 V
4
1
2 - 3 D ry C y c l e
+ 2 4 V
3
S KT 1
S KT 2
2 3
2 0
801
2
1
8 0 0
2 2
_
0
2 1
802
803
3
Reference - Control Unit Wiring Diagram
3.2

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V
E X H
S U P
P R
A
Too l
S u p ply
6 m m O D
6 m m O D
6 m m O D
6 m m O D 6 m m O D
Reference - Control Unit Pneumatic Diagram
3.3

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Name of manufacturer: HCLFastenersLtd
Address of manufacturer: FirstAvenue,WesteldIndustrialEstate,Radstock,Bath,BA34BS,UK
Telephone: +44(0)1761417714
Email: [email protected]
WeherebydeclarethatthefollowingmachineryisinconformitywiththeMachineryDirective2006/42/EC:
Machinery description: Control Unit
Part No: PT-CB-02
Serial No: PT-CB-02- -
Applied Harmonised Standards:
Ref. No. Title
BS EN 12100:2010 Safety of machinery. General principles for design.
Risk assessment and risk reduction
BS EN ISO 4414:2010 Pneumaticuidpower.Generalrulesandsafetyrequirements
for systems and their components
InAccordancewithBSENISO/IEC17050-1:2010
BSENISO4414:2010 Pneumaticuidpower.Generalrulesrelatingtosystems
BSEN60204-1:2018 SafetyofMachinery.Electricalequipment&machines
BSEN50565-1:2014 Useforcableswithratedvoltagenotexceeding450/750V
I hereby declare that the equipment named above has been designed to comply with the relevant sections
oftheabovereferencedspecicationsandisinaccordancewiththerequirementsoftheDirective.
Name: David Coles
Position: Managing Director
Address: FirstAvenue,WesteldIndustrialEstate,Radstock,Bath,BA34BS,UK
Date: 1stJuly2018
The technical documentation for the machinery is available from the above address.
Year of
manufacture
Consecutive
number
Document reference
No. CE-1000
CE Marking - EC Declaration of Conformity
EC Declaration of Conformity
In accordance with EN ISO 17050-1-2004
4.1

Considerable effort has been made to ensure that this product conforms to our high quality standards. However, should you
experience any diculties, please contact your Sales representative providing samples and the serial code specied on the tool.
HCL – UK & Rest of the World
Tel:+44(0)1761417714
Fax:+44(0)1761417710
Email: [email protected]
HCL – North America
Tel:281-717-1145
Fax:281-717-1146
Email: [email protected]
Visit www.hclfasteners.com to view our complete range of products.
November2020
©HCLFasteners.AllRightsReserved.
Your attention is drawn to the following:
HCLwarrantsthatanewHCLbandingtoolwilloperateperfunctionalspecicationsforaperiodofsixty(60)days
after the date of shipment to the owners place of business. Normal wearing parts, as outlined in the Operations,
Parts&Safetymanual,arealsocoveredbyasixty(60)daywarrantyunless,inHCL’sjudgement,thesepartshave
beensubjectedtoabnormalorextremeusage.HCL’ssoleliabilityhereunderwillbetorepairorreplace,without
charge,F.O.B.HCL,BathUK,anytoolwhichprovestonotoperateperfunctionalspecicationswithinthestated
period.HCLreservestherighttoreplaceanytoolwhichprovesnottooperateperfunctionalspecications
withaneworlike-newtoolofthesamemodel,ifinHCL’sjudgementsuchreplacementisappropriate.Anynew
replacementorlikenewreplacementtoolprovidedtoanownerwillcarryafullsixty(60)daywarranty.Anywarranty
repairedtoolwillcarryawarrantyforthebalanceoftimeremainingontheinitialsixty(60)daywarranty.This
warrantywillbeextendedtocompensateforthetimethetoolisinHCL’spossessionforwarrantyrepairs.
This warranty is void as to any tool which has been:
a)usedonnon-genuineHCLhoseclamps
b)subjectedtomis-use,misapplication,accidentdamage,orrepairedwithotherthangenuineHCLreplacement
parts.
c) improperly maintained, or adjusted, or damaged in transit or handling.
d)usedwithimproperlyltered,regulated,unlubricatedair.
e)inHCL’sopinion,alteredinawaythataffectsordetractsfromtheperformanceofthetool.
HCLMAKESNOWARRANTY,EXPRESSEDORIMPLIED,RELATINGTOMERCHANTABILITY,FITNESSOR
OTHERWISEEXCEPTASSTATEDABOVEANDHCL’SLIABILITYASASSUMEDABOVEISINLIEUOFALLOTHERS
ARISINGOUTOFORINCONNECTIONWITHTHEUSEANDPERFORMANCEOFTHETOOL.ITISEXPRESSLY
UNDERSTOODTHATHCLSHALLINNOEVENTBELIABLEFORANYINDIRECTORCONSEQUENTIALDAMAGES
INCLUDING,BUTNOTLIMITEDTO,DAMAGESWHICHMAYARISEFROMLOSSOFANTICIPATEDPROFITSOR
PRODUCTION,SPOILAGEOFMATERIALS,INCREASEDCOSTSOFOPERATIONOROTHERWISE.