Schleuniger UniCrimp 208 User manual

Operating Manual | Edition 000A (11-2022) | UniCrimp 208 1 | 64
UniCrimp 208
Crimping machine
Operating Manual
Software Version 2.0x |Edition 000A (11-2022)

Address | distributors
2 | 64
Operating Manual | Edition 000A (11-2022) | UniCrimp 208
Schleuniger AG
Bierigutstrasse 9
3608 Thun
Switzerland
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger AG
Riedstrasse 8
6330 Cham
Switzerland
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger GmbH
Raieisenstrasse 14
42477 Radevormwald
Germany
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger Test Automation GmbH
Steinung 3.1
71131 Jettingen
Germany
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger, Inc.
87 Colin Drive
Manchester, NH 03103
USA
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger Japan Co., Ltd.
1726-15, Higashi-Naganuma,
Inagi-city, Tokyo
Japan
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger Trading (Shanghai) Co., Ltd.
108, BH Center
No 7755 Zhongchun Rd
Minhang Qu, Shanghai Shi 201101
China
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger Machinery (Tianjin) Co., Ltd.
A-101 & B-101, D9 Building, No 1 Xuefu West Rd
Xuefu Industrial Zone
Xiqing Qu, Tianjin Shi 300392
China
P [phone]
[e-mail]
www.schleuniger.com
Original Instructions
The German edition of this document is the original Instructions.
Translation of the original Instructions
All non German language editions of this document are translations of the original Instructions.
© 2023 Schleuniger | ID-0000000752-002-EN
Fallback language: EN |

Table of contents
Operating Manual | Edition 000A (11-2022) | UniCrimp 208 3 | 64
TABLE OF CONTENTS
1GENERAL 6
1.1 MANUFACTURER .............................................................6
1.2 PRODUCT TYPE ..............................................................6
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS ...........................6
1.3.1 Contents..................................................................... 6
1.3.2 Safekeeping...................................................................7
1.4 SYMBOLS ................................................................... 7
1.5 LEGEND .....................................................................8
1.6 DECLARATION OF CONFORMITY ...............................................8
1.7 LIMITATION OF LIABILITY ......................................................9
1.8 WARRANTY STATEMENTS AND POLICIES ........................................9
1.9 COPYRIGHT PROTECTION .....................................................9
1.9.1 Trademarks................................................................... 9
1.10 SPARE PARTS ................................................................ 9
2SAFETY 10
2.1 TARGET AUDIENCES .........................................................10
2.2 WARNING NOTICES ..........................................................11
2.3 CAUTION PROPERTY DAMAGE ................................................11
2.4 GENERAL SAFETY NOTES .....................................................12
2.5 RESIDUAL RISKS .............................................................12
2.6 SAFETY SYMBOLS IN MANUAL ................................................13
2.7 SAFETY SYMBOLS ON PRODUCT ..............................................13
2.8 SAFETY INSTALLATIONS ......................................................13
2.9 RETROFITTING ..............................................................13
2.10 PERSONAL PROTECTIVE EQUIPMENT ..........................................13
3TRANSPORTATION 15
3.1 PACKAGING ................................................................ 15
3.2 PACKAGING SIGNS (STICKERS) ................................................15
3.3 TRANSPORT INSPECTION .................................................... 16
4PRODUCT SPECIFICATIONS 17
4.1 APPLICATION PURPOSE ......................................................17
4.1.1 Intended usage of product.......................................................17
4.1.2 Reasonably foreseeable misuse....................................................17
4.2 DIMENSIONS AND WEIGHT ...................................................18
4.3 PLANNING DATA ............................................................19
4.3.1 Positioning / mounting..........................................................19

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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
4.4 RATING PLATE .............................................................. 19
4.5 TECHNICAL DATA ........................................................... 20
4.5.1 Technical data................................................................ 20
5PRODUCT DESCRIPTION 21
5.1 CONCEPT ...................................................................21
5.1.1 Crimp connection..............................................................21
5.1.2 Applications, examples..........................................................21
5.1.3 Processing procedure...........................................................22
5.1.4 Properties....................................................................22
5.1.5 Options..................................................................... 22
5.2 OVERVIEW OF ASSEMBLIES ...................................................23
5.2.1 Switching the machine ON/OFF................................................... 23
5.2.2 Front view................................................................... 24
5.2.3 Rear........................................................................26
5.3 SAFETY ELEMENTS ..........................................................27
5.4 DANGER ZONES .............................................................28
6INSTALLATION / FIRST COMMISSIONING 29
6.1 SAFETY INSTRUCTIONS ......................................................29
6.2 UNPACKING / POSITIONING THE MACHINE .....................................30
6.3 CONNECTIONS ..............................................................30
6.3.1 Power connection..............................................................30
7GENERAL HANDLING / OPERATION 32
7.1 GENERAL TOPICS FOR THE OPERATION ........................................32
7.1.1 Safety instructions............................................................. 32
7.1.2 Switching on the machine....................................................... 32
7.1.3 Switching o the machine....................................................... 32
7.1.4 Tasks after use................................................................ 32
7.2 PREPARATION ...............................................................33
7.3 STARTING THE PRODUCTION .................................................33
7.4 SETUP ..................................................................... 34
7.4.1 Tool replacement.............................................................. 34
7.4.2 Settings..................................................................... 42
8CONTROL SOFTWARE 43
9DIAGNOSTICS / TROUBLESHOOTING 44
9.1 GENERAL FAULT LOCALIZATION ...............................................44
9.1.1 Safety instructions............................................................. 44
9.1.2 Behavior in case of an error.......................................................44
9.2 OTHER MACHINE FAULTS .....................................................44
9.3 SOFTWARE DIAGNOSTICS ....................................................45
9.4 ACTIONS AFTER SOLVING ERRORS ............................................ 45
9.5 DRAWINGS / CIRCUIT DIAGRAMS / FLOW CHARTS ...............................45

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10 MAINTENANCE / MAINTENANCE SCHEDULE 46
10.1 CUSTOMER SERVICE .........................................................46
10.2 MAINTENANCE SCHEDULE ...................................................46
10.3 DAILY MAINTENANCE ........................................................47
10.3.1 Cleaning.....................................................................47
10.4 MAINTENANCE / REPAIR WORK ...............................................48
11 SPARE PARTS / EXPLODED VIEW DRAWINGS 53
12 DECOMMISSIONING / DISPOSAL 54
12.1 DECOMMISSIONING .........................................................54
13 APPENDIX 56
13.1 BLOCK DIAGRAM ............................................................56
13.2 TABLE OF GRAPHICS .........................................................57
13.3 TABLE OF CHARTS ...........................................................58
INDEX 61

1. General
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
GENERAL
Thank you for your trust in the Schleuniger Technique. You have acquired a high performance Schleu-
niger product, designed and manufactured in our factory to your needs.
Read through this manual with due care and attention. It contains important tips and safety instruc-
tions, which allow precise and reliable production.
1.1 MANUFACTURER
In this Manual, Schleuniger AG Thun, Switzerland is referred to as manufacturer and abbreviated with
„Schleuniger“.
Schleuniger AG Phone: [phone]
Bierigutstrasse 9 Fax: [phone]
3608 Thun E-mail: [e-mail]
Switzerland Web: www.schleuniger.com
1.2 PRODUCT TYPE
This manual is valid for the following products/models:
Crimping machine UniCrimp 208
The applicable product type and the manufacture year can be found on the rating plate or the EG
declaration of conformity. See “EU-Declaration of Conformity (Register 2)“ of the ring binder.
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS
We have taken every possible measures to ensure the accuracy and completeness of this documenta-
tion. Since errors can be avoided despite the diligence never fully, we are always grateful for any
advice and suggestions.
This manual is stated as "Operating Instructions” according to the machinery directive
2006/42/EU" and is part of the product. It contains all the relevant information necessary to oper-
ate the product eciently and safely as intended.
The following phases of the product life cycle are described:
●Transport
●Commissioning
●Operating units
●Maintenance
●Disposal
Observe the safety regulations and instructions. The local accident preventions and safety regula-
tions must be observed.
If the product changes hands, the Operating Instruction must be handed over to the new owner.
Published modications and corrections from the manufacturer must be complemented. Inform
at your local Schleuniger distributor.
1.3.1 Contents
General
Each person using the product must be properly trained and have read and understood the operating
instructions. This is also imperative, even when the respective person has operated such a product or
similar previously and where they have been trained by the manufacturer.

1. General
Operating Manual | Edition 000A (11-2022) | UniCrimp 208 7 | 64
The operating instructions are no longer valid, if any of its contents (except a Quick Start Card, where
available) are removed or is changed on the data storage medium.
The following is considered to be the operating instructions:
The complete content of the ring binder according to the register directory in printed form.
The les of the documents according to "Construction (Page 7)" on a data storage medium.
Construction
The Operating Instructions consist of the following parts:
Reference Manual UniCrimp 208
The Reference Manual contains all information to the product. It serves as a learning- and general ref-
erence work for the personnel.
Contents
Safety
Description of the product
Transport
Commissioning
Operating units
Troubleshooting
Maintenance
Disposal
Target audiences
Operator
Qualied personnel
Technical specialist
Parts catalog
The parts catalog contains the following.
Contents
Options
Parts subject to wear and tear
Spare parts
Exploded view drawings and parts lists of modules
Target audiences Technical specialists
1.3.2 Safekeeping
Keep the Operating Instructions nearby of the product and safe against immissions.
The instructions must be available for the operating personnel at all times.
The contents must remain clearly legible beyond the expected lifespan of the product.
1.4 SYMBOLS
The symbols are placed in the marginal notes column and refer to the adjacent text. They have the
following meaning:

1. General
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
Symbol Meaning Description
Info Information which helps to operate the product eciently and error-
free.
Maintenance Maintenance tasks
Recycle Recycle parts. Do not dispose o to regular waste.
Tip Recommendations and tips which improve the intended utilization
of the product.
Dispose.o Environmental contaminating substances to return to supplier.
1.5 LEGEND
In the text, mark-up is used in the following manner.
Markup Meaning Description
[KEY] Key / button Key commands and buttons on screen representa-
tions are in the text shown in squared brackets, capital
letters and orange colored.
„Conguration“ Screen title / menu Screen titles and menus are represented in the text in
"quotation marks".
"1.5 Legend (Page 8)" Cross referencing Cross referencing are represented in blue and italic.
1.▹Activity direction Activity directions are a summary of activity steps
with an arrow.
➥Consequence of an
activity direction
Results or released actions in activity directions are
represented with a leading arrow.
The following abbreviations are used.
Abbreviation Meaning Description
Fig. Figure Figures are captioned as "Fig.” in the picture title.
Tab. Table Tables are captioned as "Tab."
mm Millimeter All Measures in the manuals are given in millimeters.
CW Clockwise Direction of rotation for a component or an operating
element viewed from rotation axis.
CCW Counter clockwise Direction of rotation for a component or an operating
element viewed from rotation axis.
1.6 DECLARATION OF CONFORMITY
See document “EG-Declaration of Conformity (Register 2)“ of the ring binder.

1. General
Operating Manual | Edition 000A (11-2022) | UniCrimp 208 9 | 64
1.7 LIMITATION OF LIABILITY
The content of these Operating Instructions was put together taking into consideration the current
standards and guidelines according to the state of the technology and our many years of experience.
The manufacturer disclaims any liability for damages and accidents as a result of:
Disregard of the instructions
Disregard of safety regulations
Non-intended usage
1.8 WARRANTY STATEMENTS AND POLICIES
See Schleuniger document „General Conditions of Sale and Delivery”.
1.9 COPYRIGHT PROTECTION
Keep this operating instructions condentially. It is intended for the exclusive use of persons operat-
ing the product. Without written agreement, this instructions shall not be made available to third par-
ties.
The content of the operating instructions in the form of text, illustrations, drawings, circuit diagrams
or other presentation, is protected by copyright law of the manufacturer.
1.9.1 Trademarks
The WinCrimp quality assurance software is a trademark of Schleuniger Messtechnik.
Windows® is a registered trademark of Microsoft corporation in the USA and other countries.
The rights to brands and product names mention in this manual rest with their owners and are hereby
acknowledged. Mentioning of products not from Schleuniger is done for informational purposes only.
It does not constitute any advertising. Schleuniger does not assume any guaranty regarding the
selection, performance or usability of these products. Protected trademarks are not expressly indica-
ted in the manual. However, this does not mean that they can be used freely.
1.10 SPARE PARTS
Always order original spare parts from your local Schleuniger representative.
Any modications in design or function of the spare parts, in terms of ongoing product improvement,
are subject to change without prior notication.
CAUTION
Use of unveried spare parts!
Unveried or defective spare parts can lead to personnel injury or property damage.
To avoid any damage, exclusive use of original Schleuniger spare parts is imperative.

2. Safety
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
SAFETY
2.1 TARGET AUDIENCES
This operating instruction is intended for individual target audience. Certain chapters therefore are
withhold for a particular target audience and mentioned accordingly in the introductional section.
Only this group is authorized to carry out the appropriate tasks. The other contents generally is inten-
ded for all audience and is not stated specially.
The product is intended to be operated by persons older than 14 years. Younger persons are not
allowed to operate the product.
The Target audiences must have the following skill. Thus have the competence to carry out certain
activities
Operating company
Qualication
Higher level juristic person
Authority to give directives
Dene competences
Authority / activity
Teaching
Deploy authorized personnel
Use product according to the intended usage
Technical specialists
Technical specialist / service tech-
nician
Mechanical and electrical basic education
Product-specic training
Know-how in wire processing technics
Authority / activity
Unpacking
Installation
Commissioning, start-up
Operating
Programming
Maintenance and repair
Disposal
Qualied personnel
Qualication
Technical skill
Product-specic training
Know-how in wire processing technics
Authority / activity
Operating
Programming
Instructor
Maintenance

2. Safety
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Operating personnel
Qualication
Product-specic training
Accident prevention
First aid assistance
Authority / activity Operating
Clean
Third party
Externally called in personnel of the operating company, service technicians and sta from
Schleuniger.
Qualication Mechanical and electrical education
Specialist in wire processing technology
Authority / activity
Commissioning, start-up
Maintenance and repair
Repair
Modications
2.2 WARNING NOTICES
The warning notices in the entire operating instructions are marked with the warning banner and the
appropriate danger symbol. The following three endangering levels are primarily distinct by the sig-
nal word.
Compulsory comply the warning notices to avoid accidents and personnel injury.
DANGER
Warning notice „Danger”
This panel indicates a hazardous situation, which if not avoided, will result in
death or serious injury.
WARNING
Warning notice „Warning”
This panel indicates a hazardous situation, which if not avoided, could result in
death or serious injury.
CAUTION
Warning notice „Caution“
This panel indicates a potential hazardous situation, which if not avoided, may
result in minor or moderate injury.
2.3 CAUTION PROPERTY DAMAGE
NOTICE
"Property damage"
This panel indicates a hazardous situation, which if not avoided, can result in
damage to property.

2. Safety
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
2.4 GENERAL SAFETY NOTES
The machine has been designed in accordance with the European standard EN ISO 12100:2010 for
persons over 14 years of age and without physical restrictions. It is strictly forbidden to grant
access to the machine by younger persons.
The product must only be operated when in good working order and condition. It must be
checked for intactness prior to the start of operation.
Never operate the product in environments where there is a risk of re or explosion.
Operate the product only in dry, dust-free rooms.
Processing of carbon bers or similar conductor material releases minute electrically conductive
particles. They can cause short circuits in the electronics. Electronic components may be seriously
damaged as a result. Use suitable extraction facilities.
Before carrying out any maintenance or repair work, disconnect the machine from the mains
and/or from the compressed air supply.
After any maintenance work, to which the machine housing has to be opened, always carry out
the safety check.
Operate the product always with the ground connector connected in the power cord.
Only use original Schleuniger equipment, especially interface connection cables (electromagnetic
compatibility).
Use lubricants lubricants solely according to the specications in the manual.
Preventive maintenance and modication tasks must be carried out by appropriately qualied
sta.
The safety data sheets can be accessed under:
www.schleuniger.com/de/safety-data-sheets/ .
2.5 RESIDUAL RISKS
There are dangers associated with the use of technical products. Hazards that could neither be elimi-
nated by constructive measures nor by protective devices are residual risks. The safety instructions in
this manual refer to the known residual risks. Should additional dangers arise during operation, the
operator is obliged to inform Schleuniger company immediately.
The following residual risks may occur under certain circumstances:
Danger of tripping, falling and slipping caused by connecting cables, wire waste, air hoses and
objects lying on the oor.
●Install wires and hoses orderly arranged
●Catch wire waste
●Keep work area clear from objects scattered about
Risk due to increased noise level while working in an environment with multiple machines.
●Take up noise control measures!
Certain wires contain talcum. It is released during wire processing and pollutes the working envi-
ronment.
●Use extraction facility
●Wear dust mask
Injuries of the user and malfunctions on the product may occur due to inadequate maintenance
of the product.
Danger of insucient illumination on the working location.
●Illuminate the working location accordingly
●Equip the machines with the optional illumination.

2. Safety
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2.6 SAFETY SYMBOLS IN MANUAL
In this manual, the warning hints are supplemented with the following symbols. They refer to poten-
tial danger.
Symbol Meaning Description
Electric power! There is a danger of electric shock by contact with the mains
socket and parts inside the product. Therefore before open-
ing the product always switch o the main switch and
unplug it from the mains. Touching electric components can
cause injury to the operator personnel.
General danger! Notes and instructions with this safety symbol should be fol-
lowed strictly. Disregarding may lead to injury and damage
to the machine.
Danger area pro-
cessing compart-
ment!
There is a general risk of injury from rotating parts in the pro-
cessing area.
When reaching into the feeding area during production, the
user can infringe on the ngers.
Electrostatic sensi-
tive components!
Electronic components react sensitive to static charge. Spe-
cially marked components and packaging must only be han-
dled by trained personnel after a potential equalization and
with special equipment.
2.7 SAFETY SYMBOLS ON PRODUCT
There are warning symbols on the product. They advise the user about potential danger. An overview
of the stickers can be found in chapter "5 Product description (Page 21)".
2.8 SAFETY INSTALLATIONS
The built in safety interlocks on the product (safety, protection, monitoring) must not be removed, by-
passed or changed. Check the safety appliances in certain intervals. Defective safety equipment's
must be xed immediately.
Never operate the product with open covers.
Never operate the product if the safety cover is open.
2.9 RETROFITTING
Without written permission of Schleuniger, do not make changes or any retrot work on the machine.
The performance and the safety of the product is aected thereby.
Standard options and accessories supplied by Schleuniger are excluded therefrom.
2.10 PERSONAL PROTECTIVE EQUIPMENT
While working on the product, the personnel must be protected from injury or disease.
Observe the local regulations and instructions of the operating company
The following protective equipment is recommended

2. Safety
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
Symbol Meaning Description
Eye protection Wear safety classes. This protects the eyes from small parti-
cles produced during the cutting procedure.
Wear protective
headgear
Wear hair net or safety hood. Long hair may get caught by
moving machine parts.

3. Transportation
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TRANSPORTATION
Personnel qualication
The instructions in this chapter must be carried out by technical specialists!
3.1 PACKAGING
The packaging provides enough protection during transport with common means of transportation.
It consists of:
Wooden box
Store the packaging for later use on a weatherproof location.
Recycle the unneeded packaging.
NOTICE
Inadvertently transportation of the product can lead to property damage.
Handle the packaging with care
Observe the packaging signs
Wherever applicable remove the packaging not before placing on site of operation
3.2 PACKAGING SIGNS (STICKERS)
The following packaging symbols are axed to the packaging.
Symbol Meaning Description
Fragile Handle the container with caution. Avoid strong vibrations
and pressure.
This way up The arrows point to the top side of the containers. Store and
transport the container upright. Do not tip.
Keep dry Store and transport the container against moisture.

3. Transportation
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
3.3 TRANSPORT INSPECTION
Check the goods immediately after receiving for completeness and loss during shipment.
On recognizable loss during shipment proceed as follows:
Do not accept the delivery or only with retentions
Declare loss of shipment
Immediately report damages on the product to the shipping company or the vendor

4. Product specications
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PRODUCT SPECIFICATIONS
4.1 APPLICATION PURPOSE
4.1.1 Intended usage of product
The product UniCrimp 208 is exclusively determined for processing of following materials:
Wire
Solid
The materials must be treated in the following way:
Crimping
See also chapter "5.1.2 Applications, examples (Page 21)".
As limits the areas in the technical data apply. Any other use of this product is regarded as non-inten-
ded use. For damages arising therefrom, Schleuniger is not liable.
4.1.2 Reasonably foreseeable misuse
The product is not intended for the processing of materials with the following characteristic:
Explosive
Flammable
Toxic

4. Product specications
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
4.2 DIMENSIONS AND WEIGHT
Fig. 1: Dimensions
Specication Value Unit
Weight Net (base unit) 85 kg
Measures Depth (B) 320 mm
Width (A) 401 mm
Height (C) 708 mm
Center of gravity Upper area (approx. 10cm from the top) in
the center of the machine.
When packaged, note marking on packag-
ing.
Tab. 1: Dimensions/weight

4. Product specications
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4.3 PLANNING DATA
4.3.1 Positioning / mounting
After unpacking, put the machine onto a at working space (table, work bench, etc.). Secure the
machine from slipping o during operation.
Over temperature condition may occur if the fan exhaust is blocked in any way. Do not block or cover
the ventilator exhaust. A distance of at least 30cm to the next object should be maintained, to let the
cooling air ow freely.
4.4 RATING PLATE
To ensure our ecient support, we request the customer to always submit the exact content of the
rating plate when contacting us with requests.
The rating plate with the serial number and the electrical data is on the left side.
It contains the following details:
13
47
5
26
1
Product type
2
Serial number/year
3
Permissible operating voltage
4
Line frequency
5
Machine weight
6
Power consumption
7
Internal fuse protection

4. Product specications
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Operating Manual | Edition 000A (11-2022) | UniCrimp 208
4.5 TECHNICAL DATA
The technical data correspond to the theoretical values and are achievable under normal conditions.
Any modications in design or function, in terms of ongoing product improvement, are subject to
change without prior notication.
4.5.1 Technical data
Specication Value
Press force 33 kN
Output 0.75 kW
Cross section range Up to 10 mm2 (8 AWG), material thickness 1 mm / length of crimping
zone 8 mm
Stroke 40 mm (optional 30 mm)
Crimp height 135,788 mm
Height adjustment range
(crimp height)
Continuously variable ± 0.25 mm, in increments of 0.025 mm
Cycle time 0.35 ms to 1 s (adjustable)
Press activation Pedal
Compressed air 4 to 5 bar
Noise level < 70 dB (A)
Mains connection 230/240 VAC (optionally 100/115 VAC)
Power frequency 50/60Hz
Power consumption 255 VA
Ambient temperature +5 °C to +40 °C
Storage and transport tem-
perature
-25 °C to +55 °C
Relative humidity 90% at 20 °C / 50% at 40 °C