Schleuniger CrimpCenter 36 SP Installation instructions

Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP 1 | 190
CrimpCenter 36 SP
Base Machine
Original Operating Manual
Edition 1.0 (03-2018)

Address / distributors
2 | 190
Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP
Schleuniger GmbH
Raieisenstrasse 14
42477 Radevormwald
Germany
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger AG
Bierigutstrasse 9
3608 Thun
Switzerland
P [phone]
F [phone]
[e-mail]
www.schleuniger.com
Schleuniger AG
Gewerbestrasse 14
6314 Unteraegeri
Switzerland
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-na.com
Schleuniger Japan Co., Ltd.
1726-15, Higashi-Naganuma,
Inagi-city, Tokyo
Japan
P [phone]
F [phone]
[e-mail]
www.schleuniger.co.jp
Schleuniger Trading (Shanghai) Co., Ltd.
108, BH Center
7755 Zhongchun Rd
Shanghai, 201101
China
P [phone]
F [phone]
[e-mail]
www.schleuniger.cn
Schleuniger Machinery (Tianjin) Co., Ltd.
No.8, High-tech Development 3rd street
Huayuan Industry Development Area (Huanwai)
Xiqing District, Tianjin 300392
China
P [phone]
[e-mail]
www.schleuniger.cn
© 2018 Schleuniger | ID-0000000410-006-EN
Part #: 475 599

Table of contents
Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP 3 | 190
TABLE OF CONTENTS
1GENERAL 8
1.1 MANUFACTURER .............................................................8
1.2 MANUFACTURING DATE/PRODUCT TYPE ....................................... 8
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS ...........................8
1.3.1 Contents of the manual.......................................................... 8
1.3.2 Depository....................................................................9
1.3.3 Responsibilities................................................................ 9
1.4 GENERAL SYMBOLS AND LEGEND ..............................................9
1.4.1 References and Hints............................................................ 9
1.4.2 Legend......................................................................10
1.5 EC DECLARATION OF CONFORMITY / DECLARATION OF INCORPORATION .........10
1.6 LIMITATION OF LIABILITY .....................................................10
1.7 WARRANTY STATEMENTS AND POLICIES .......................................11
1.8 COPYRIGHT PROTECTION ....................................................11
1.8.1 Trademarks.................................................................. 11
1.9 SPARE PARTS ............................................................... 11
1.10 VALIDITY ...................................................................12
1.11 MISUSE AND MODIFICATIONS ................................................12
1.12 ENVIRONMENTAL PROTECTION ...............................................12
1.13 TECHNICAL SUPPORT ........................................................12
1.14 UPDATING ..................................................................13
2SAFETY 14
2.1 WARNING NOTICES ..........................................................14
2.2 SAFETY REGULATIONS .......................................................14
2.3 SOURCES OF DANGER / RESIDUAL RISKS .......................................15
2.4 INTENDED USAGE OF PRODUCT ..............................................17
2.5 REASONABLY FORESEEABLE MISUSE .......................................... 17
2.6 SAFETY SYMBOLS ...........................................................18
2.7 SAFETY MARKING ...........................................................19
2.8 MODIFICATION AND RETROFITTING OF THE PRODUCT ..........................19
2.9 RESPONSIBILITIES ...........................................................19
2.10 PERSONNEL QUALIFICATION ................................................. 20
2.10.1 Personnel classication..........................................................20
2.10.2 Tasks / Authorities............................................................. 22
2.11 PERSONAL PROTECTIVE EQUIPMENT ..........................................23
2.11.1 Eye protection................................................................ 23
2.11.2 Protective clothes..............................................................23
2.11.3 Safety Shoes..................................................................23

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2.11.4 Safety Gloves................................................................. 23
2.11.5 Snood-type Cap / Safety Cover.................................................... 23
2.12 SAFETY INSTALLATIONS ......................................................23
3TRANSPORT / PACKAGING / STORAGE 24
3.1 SAFETY DIRECTIONS FOR THE TRANSPORT .....................................25
3.1.1 Arbitrary transport............................................................. 25
3.1.2 Improper transportation.........................................................25
3.2 TRANSPORT INSPECTION .................................................... 25
3.3 UNPACKING / LOADING ......................................................26
3.4 LIFTING POINTS .............................................................26
3.5 PACKAGING ................................................................ 27
3.5.1 Storage..................................................................... 27
3.5.2 Disposal.....................................................................27
3.6 INTERNAL TRANSPORTATION .................................................27
3.7 STORAGE ...................................................................27
4PRODUCT SPECIFICATIONS 29
4.1 DIMENSIONS AND WEIGHT ...................................................29
4.2 TECHNICAL SPECIFICATIONS ................................................. 29
4.3 PLANNING DATA ............................................................30
4.3.1 Installation Location............................................................30
4.3.2 Electric and Pneumatic Connection.................................................32
4.3.3 Position of the supply...........................................................32
4.4 MACHINE AREAS ............................................................32
4.5 RATING PLATE .............................................................. 34
5PRODUCT DESCRIPTION 35
5.1 OVERVIEW ..................................................................35
5.2 EQUIPMENT OPTIONS ....................................................... 36
5.2.1 Assemblies of the Base Machine................................................... 36
5.2.2 Processing Stations and Options...................................................39
5.3 PROCESSING CAPABILITIES ...................................................39
5.3.1 Available Processing Stations..................................................... 40
5.3.2 Available Quality Assurance...................................................... 41
5.4 SAMPLE CONFIGURATIONS ...................................................43
5.4.1 Sample Conguration 1......................................................... 43
5.4.2 Sample Conguration 2......................................................... 44
5.4.3 Sample Conguration 3......................................................... 44
5.4.4 Sample Conguration 4......................................................... 45
5.4.5 Sample Conguration 5......................................................... 46
5.4.6 Sample Conguration 6......................................................... 47
5.5 PROCESSING STATIONS AND OPTIONS .........................................48
5.5.1 Overview of available Stations.................................................... 48

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5.6 AVAILABLE OPTIONS .........................................................57
5.6.1 Depositing Table.............................................................. 58
5.7 SCOPE OF DELIVERY .........................................................59
5.7.1 Product..................................................................... 59
5.7.2 Required Basic Equipment....................................................... 59
5.8 BLADES ....................................................................60
6SAFETY ELEMENTS / DANGER AREAS 61
6.1 SAFETY COVER - PUSHBUTTON AND CONFIRM BUTTON .........................62
6.2 EMERGENCY STOP SWITCH ...................................................64
6.3 SAFETY COVER SWITCH ......................................................65
6.4 DANGER ZONES GENERALLY ..................................................66
6.4.1 Danger Zones when Safety Cover is closed........................................... 67
6.4.2 Danger zones when Safety Cover is open............................................ 68
7INSTALLATION / MOUNTING 70
7.1 SAFETY INSTRUCTIONS ......................................................70
7.2 POSITIONING / (DIS-) MOUNTING .............................................72
7.2.1 Installing the Touch Screen....................................................... 72
7.2.2 Removing the Conveyor Belt......................................................73
7.2.3 Mounting of the guide rods...................................................... 73
7.3 ELECTRIC INSTALLATION .....................................................74
7.3.1 Control cabinet................................................................74
7.4 PROCESSING STATIONS ......................................................77
8COMMISSIONING 78
8.1 STARTING CONDITIONS ......................................................79
8.2 PROTECTIVE GUARD PLATES ..................................................81
8.3 MOUNTING THE TOOLINGSHUTTLE ...........................................88
8.4 ACTIVATE THE CRIMPCENTER .................................................88
8.5 OPEN THE SAFETY COVER ....................................................89
8.6 CONFIRM BUTTONS .........................................................89
8.7 ADJUST THE WORKING HEIGHT OF THE UNICRIMP 221/222 ......................90
8.8 MOUNT THE GUIDE TUBES ...................................................91
8.9 INSERT WIRE ................................................................93
8.10 ADJUST THE CONTACT PRESSURE OF THE WIRE FEED ............................98
8.11 ADJUST THE CLAMPING FORCE OF THE GRIPPER ................................99
8.12 CONVEYOR BELT ........................................................... 101
8.13 REFERENCING ..............................................................103
8.13.1 Cutting Unit and Swivel........................................................ 103
8.13.2 Deposit Gripper.............................................................. 112
8.13.3 Crimp station................................................................ 117

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8.14 TOWERLIGHT ..............................................................123
9SERVICING / MAINTENANCE 125
9.1 INTRODUCTION ............................................................125
9.2 SAFETY INSTRUCTIONS .....................................................126
9.2.1 General Safety Advice..........................................................126
9.2.2 Personnel qualication.........................................................127
9.2.3 Personal protective equipment...................................................127
9.3 CUSTOMER SERVICE ........................................................128
9.3.1 Technical Support.............................................................128
9.3.2 Trouble Shooting Procedure.....................................................128
9.4 MAINTENANCE TABLE: BASE MACHINE ........................................128
9.5 MAINTENANCE SHEET - CHECK SAFETY DEVICES ...............................130
9.5.1 Main switch................................................................. 130
9.5.2 Emergency Stop Switch........................................................ 131
9.5.3 Conrm Buttons..............................................................134
9.5.4 Safety Cover Pushbutton........................................................135
9.5.5 Safety Cover Switch........................................................... 137
9.5.6 Safety Cover.................................................................139
9.5.7 Safety Cover.................................................................140
9.5.8 Motors..................................................................... 141
9.5.9 Pneumatic.................................................................. 145
9.5.10 Conveyor Belt................................................................146
9.5.11 Power Sockets............................................................... 147
9.6 MAINTENANCE SHEET - CHECK MACHINE .....................................149
9.7 MAINTENANCE SHEET - SURFACE CLEANING AND PREVENTION .................150
9.7.1 Touch Screen................................................................ 151
9.7.2 PET - Surfaces................................................................152
9.7.3 Plastic / Rubber / Eladur........................................................ 153
9.7.4 Steel Surfaces - Stainless Steel (V2A)............................................... 154
9.7.5 Steel Surfaces - Crude Steel (not gliding)............................................154
9.7.6 Steel Surfaces - Crude Steel (guide rails)............................................ 155
9.7.7 Steel Surfaces - Nitried Steel.................................................... 156
9.7.8 Zinc Coated Surfaces.......................................................... 157
9.7.9 Aluminum Surfaces........................................................... 158
9.7.10 Powdered / Painted Surfaces.....................................................159
9.7.11 Tinning Station / Surrounding Parts................................................160
9.8 MAINTENANCE SHEET - LUBRICATE GUIDE RAIL(S) ............................. 161
9.9 MAINTENANCE SHEET - CLEANING THE CUTTER BLOCKS ........................162
9.10 MAINTENANCE SHEET - EXCHANGING BLADE ................................. 164
9.11 MAINTENANCE SHEET - EXCHANGE FEEDING BELTS ............................169
9.12 MAINTENANCE SHEET - DUMP CONDENSATE ..................................172
9.13 MAINTENANCE SHEET - FILTER ELEMENT(S) ................................... 174
9.14 MAINTENANCE SHEET - CHECK CONVEYOR BELT ...............................177

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10 SPARE PARTS 178
11 DECOMMISSIONING / DISPOSAL 179
11.1 DECOMMISSIONING ........................................................179
11.2 DISASSEMBLY / DISPOSAL ...................................................180
12 OVERVIEW OF SYMBOLS 181
13 PERSONAL NOTES 185
14 ADDITIONAL DOCUMENTS 187
15 WIRING DIAGRAMS 188
INDEX 183

1. General
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Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP
GENERAL
Thank you for your trust in the Schleuniger technique! You have acquired a high perform-
ance Schleuniger 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
instructions, which allow precise and reliable wire/cable production.
1.1 MANUFACTURER
Schleuniger GmbH
Raieisenstrasse 14 Phone: [phone]
42477 Radevormwald Fax: [phone]
Germany Email: [e-mail]
Web: www.schleuniger.com
1.2 MANUFACTURING DATE/PRODUCT TYPE
See „Rating Plate“.
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS
The Operating Manual is part of the product and contains all the relevant information
necessary to operate the product eciently and safely as intended.
The mentioned safety notes and directions, as well as the valid local accident prevention
regulations and general safety regulations for the scope of application, must be com-
plied.
If the product changes hands, the Operating Manual must be supplied to the new owner.
Make sure to update any relevant safety changes and corrections to the Operating Man-
ual which are available.
Ask your local Schleuniger distributor.
1.3.1 Contents of the manual
General
Each person using the product must be properly trained and have red and understood the
Operating Manual. 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.
As operating instructions count all documents according to the index of the register in prin-
ted and / or electronic form.
The Operating Manual is no longer valid, if any of its contents (except Quick Start Card,
where available) have been removed or on the data medium are not observed.
Construction
We are trying to make the operation of our products as easy as possible. To achieve this we
have developed a concept for the Operating Manual.
The Operating Manual consists of three parts:

1. General
Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP 9 | 190
Operating Manual
A detailed Operating Manual for the product with full explanation of all functions available
and the general maintenance. The Operating Manual is meant for the beginner as well as for
the experienced user (qualied personnel) as a learning- and reference guide.
See also chapter "2.10.1 Personnel classication (Page 20)".
Operating Manual - EASY User Software
A detailed Operating Manual for the operation of the user software CrimpCenter 36 SP. The
Operating Manual is meant for the beginner as well as for the experienced user (qualied
personnel) as a learning- and reference guide.
See also chapter "2.10.1 Personnel classication (Page 20)".
Parts catalog
An overview on the components of the product. This part of the Operating Manual is inten-
ded mainly for the technical specialist.
See also chapter "2.10.1 Personnel classication (Page 20)".
1.3.2 Depository
The Operator's Handbook must be available to the operating personnel at all times. Keep
the Operator's Handbook in such a way that it will not become damaged, so that the con-
tents will remain clearly legible beyond the expected lifespan of the product.
1.3.3 Responsibilities
This Operator's Handbook must be kept near the product. It must be available to the
operating personnel at all time.
Always follow the instructions in this Operator's Handbook fully and without restraint.
1.4 GENERAL SYMBOLS AND LEGEND
1.4.1 References and Hints
The listed pictograms in the instructions have the following meaning:
Symbols
The symbols are placed in the marginal notes column and refer to the adjacent text. They
have the following meaning:
Symbol Meaning Description
Overview Detailed description or introductional chapter.
Recycle Recycle parts. Do not dispose o to regular waste.
Dispose.o Environmental contaminating substances to return to supplier.

1. General
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Original Operating Manual | Edition 1.0 (03-2018) | CrimpCenter 36 SP
1.4.2 Legend
In the text, mark-up is used in the following manner.
Mark-up Meaning Description
[SWITCH] Switch / button 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".
Schleuniger Product names and
company
Product- and company names are represented
italic.
"1.4.2 Legend
(Page 10)"
Cross referencing Cross referencing are represented in blue and
italic.
1.▹Activity direction Activity directions are a summary of activity
steps.
➥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."
mm Millimeter All Measures in the manual are given in millime-
ters.
UZS Clockwise Direction of rotation for a component or an oper-
ating element viewed from rotation axis.
GUZS Counter clockwise Direction of rotation for a component or an oper-
ating element viewed from rotation axis.
1.5 EC DECLARATION OF CONFORMITY / DECLARATION OF INCORPO-
RATION
See document „EC Declaration of Conformity“ or „Declaration of Incorporation“.
1.6 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 warning notices.
Use of the machine or processing stations not according to their intended use.
Use of parts not included in the approved product range.