Schleuniger CrimpCenter 64 SP Installation instructions

Original Operating Manual | Edition 1.0 (01-2020) | CrimpCenter 64 SP 1 | 268
CrimpCenter 64 SP
Base Machine
Original Operating Manual
Edition 1.0 (01-2020)

Address / distributors
2 | 268
Original Operating Manual | Edition 1.0 (01-2020) | CrimpCenter 64 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.
A-101 & B-101, D9 Building, No 1 Xuefu West
Road,
Xuefu Industrial Zone
Xiqing Qu, Tianjin Shi 300392
China
P [phone]
[e-mail]
www.schleuniger.cn
Original Manual
The German version of this document is the original manual.
Translation of the original manual
All non-German language editions of this document are translations of the original manual.
© 2019 Schleuniger | ID-0000000299-004-EN
Part #: 481 079

Table of contents
Original Operating Manual | Edition 1.0 (01-2020) | CrimpCenter 64 SP 3 | 268
TABLE OF CONTENTS
1GENERAL 8
1.1 MANUFACTURER .............................................................8
1.2 VALIDITY ....................................................................8
1.3 MANUFACTURING DATE/PRODUCT TYPE ....................................... 8
1.4 INFORMATION ABOUT THE OPERATING INSTRUCTIONS ...........................8
1.4.1 Contents of the manual.......................................................... 9
1.4.2 Depository....................................................................9
1.4.3 Responsibilities................................................................ 9
1.5 GENERAL SYMBOLS AND LEGEND .............................................10
1.5.1 References and Hints........................................................... 10
1.5.2 Legend......................................................................10
1.5.3 Figures......................................................................11
1.6 EC DECLARATION OF CONFORMITY / DECLARATION OF INCORPORATION .........11
1.7 LIMITATION OF LIABILITY .....................................................11
1.8 WARRANTY STATEMENTS AND POLICIES .......................................12
1.9 COPYRIGHT PROTECTION ....................................................12
1.9.1 Trademarks.................................................................. 12
1.10 SPARE PARTS ............................................................... 12
1.11 MISUSE AND MODIFICATIONS ................................................12
1.12 ENVIRONMENTAL PROTECTION ...............................................13
1.13 PRIVACY ....................................................................13
1.14 TECHNICAL SUPPORT ........................................................13
1.15 UPDATING ..................................................................14
2SAFETY 15
2.1 PERSONNEL QUALIFICATION ................................................. 15
2.1.1 Personnel classication..........................................................15
2.1.2 Tasks / Authorities............................................................. 17
2.2 RESPONSIBILITIES ...........................................................18
2.3 WARNING NOTICES ..........................................................18
2.4 INTENDED USAGE OF PRODUCT ..............................................19
2.5 REASONABLY FORESEEABLE MISUSE .......................................... 20
2.6 SAFETY MARKING ...........................................................20
2.7 SAFETY SYMBOLS ...........................................................20
2.8 PERSONAL PROTECTIVE EQUIPMENT ..........................................21
2.8.1 Eye protection................................................................ 21
2.8.2 Protective clothes..............................................................22
2.8.3 Safety Shoes..................................................................22
2.8.4 Safety Gloves................................................................. 22
2.8.5 Snood-type Cap / Safety Cover.................................................... 22

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2.9 SAFETY REGULATIONS .......................................................22
2.10 SOURCES OF DANGER / RESIDUAL RISKS .......................................23
2.11 SAFETY INSTALLATIONS ......................................................24
2.12 MODIFICATION AND RETROFITTING OF THE PRODUCT ..........................24
3TRANSPORT / PACKAGING / STORAGE 25
3.1 SAFETY DIRECTIONS FOR THE TRANSPORT .....................................26
3.1.1 Arbitrary transport............................................................. 26
3.1.2 Improper transportation.........................................................26
3.2 PACKAGING SIGNS (STICKERS) ................................................26
3.3 TRANSPORT INSPECTION .................................................... 27
3.4 UNPACKING / LOADING ......................................................27
3.5 LIFTING POINTS .............................................................28
3.6 PACKAGING ................................................................ 28
3.6.1 Storage..................................................................... 28
3.6.2 Disposal.....................................................................28
3.7 INTERNAL TRANSPORTATION .................................................28
3.8 STORAGE ...................................................................29
4PRODUCT SPECIFICATIONS 30
4.1 DIMENSIONS AND WEIGHT ...................................................30
4.2 TECHNICAL SPECIFICATIONS ................................................. 31
4.3 PLANNING DATA ............................................................32
4.3.1 Installation Location............................................................32
4.3.2 Electric and Pneumatic Connection.................................................33
4.3.3 Position of the supply...........................................................34
4.4 MACHINE AREAS ............................................................34
4.5 RATING PLATE .............................................................. 35
5PRODUCT DESCRIPTION 36
5.1 OVERVIEW ..................................................................36
5.2 BASIC EQUIPMENT .......................................................... 38
5.2.1 Process......................................................................38
5.2.2 Check.......................................................................44
5.3 OPTIONAL EQUIPMENT ......................................................45
5.3.1 Process......................................................................45
5.3.2 Check.......................................................................57
5.4 FACT SHEET ................................................................ 59
5.4.1 Available Stations..............................................................59
5.4.2 Available Options..............................................................72
5.4.3 Available Software............................................................. 79
5.4.4 Depositing Table.............................................................. 81
5.5 SAMPLE CONFIGURATIONS ...................................................82

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5.5.1 Sample Conguration 1......................................................... 82
5.5.2 Sample Conguration 2......................................................... 83
5.5.3 Sample Conguration 3......................................................... 84
5.6 SCOPE OF DELIVERY .........................................................85
5.6.1 Product..................................................................... 85
5.6.2 Required Basic Equipment....................................................... 85
6SAFETY ELEMENTS / DANGER AREAS 86
6.1 MAIN SWITCH ...............................................................87
6.2 EMERGENCY STOP SWITCH ...................................................88
6.3 SAFETY COVER ..............................................................90
6.3.1 Safety switch................................................................. 91
6.3.2 Open / close..................................................................92
6.4 CONFIRM BUTTONS .........................................................93
6.5 DANGER ZONES GENERALLY ..................................................94
6.5.1 Danger Zones when Safety Cover is closed........................................... 94
6.5.2 Danger zones when Safety Cover is open............................................ 96
7INSTALLATION / MOUNTING 97
7.1 SAFETY INSTRUCTIONS ......................................................97
7.2 POSITIONING / (DIS-) MOUNTING ............................................100
7.2.1 (De-) Mounting - Transport Aid - Upper Bracket.......................................100
7.2.2 (De-) Mounting - Transport Aid - Dual ToolingShuttle.................................. 101
7.2.3 (De-) Mounting - Straightener....................................................105
7.2.4 (De-) Mounting - Conveyor Belt...................................................106
7.2.5 (De-) Mounting - Dual ToolingShuttle (Option)....................................... 108
7.3 ELECTRIC INSTALLATION ....................................................111
7.3.1 Connections / interfaces........................................................112
7.3.2 Control cabinet...............................................................115
7.4 STATIONS ..................................................................117
8COMMISSIONING 120
8.1 OPEN THE SAFETY COVER ...................................................122
8.2 CONFIRM BUTTONS ........................................................123
8.3 COMMANDPOD ............................................................124
8.4 TOWERLIGHT ..............................................................126
8.4.1 Overview................................................................... 126
8.4.2 Service switch................................................................127
8.4.3 EASY - Description of the function.................................................127
8.4.4 EASY - Settings...............................................................129
8.5 RECOMMENDED SETTINGS ..................................................131
8.5.1 Pneumatic.................................................................. 131
8.6 STARTING CONDITIONS .....................................................132
8.7 STEP BY STEP ..............................................................134
8.7.1 Introduction.................................................................134

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8.7.2 Safety instructions............................................................ 135
8.7.3 Prerequisite................................................................. 139
8.7.4 Align the Basic Machine........................................................ 140
8.7.5 Insert and align the conveyor belt.................................................143
8.7.6 Use ToolingShuttle............................................................ 149
8.7.7 Use Dual ToolingShuttle........................................................ 150
8.7.8 Adjust the Working Height of the UniCrimp 221/222...................................152
8.7.9 Activate the CrimpCenter....................................................... 153
8.7.10 Mount the guide tubes.........................................................154
8.7.11 Insert Wire.................................................................. 159
8.7.12 Adjust the Contact Pressure of the Wire Feed.........................................163
8.7.13 Adjust the Clamping Force of the Gripper........................................... 165
8.7.14 Conveyor Belt................................................................167
8.7.15 Referencing................................................................. 171
9SERVICING / MAINTENANCE 191
9.1 INTRODUCTION ............................................................191
9.2 SAFETY INSTRUCTIONS .....................................................192
9.2.1 General Safety Advice..........................................................192
9.2.2 Personnel qualication.........................................................193
9.2.3 Personal protective equipment...................................................194
9.3 CUSTOMER SERVICE ........................................................194
9.3.1 Technical Support.............................................................194
9.3.2 Trouble Shooting Procedure.....................................................194
9.4 MAINTENANCE TABLE: BASE MACHINE ........................................195
9.5 MAINTENANCE SHEET - CHECK SAFETY DEVICES ...............................197
9.5.1 Main switch................................................................. 198
9.5.2 Emergency Stop Switch........................................................ 200
9.5.3 Conrm Buttons..............................................................203
9.5.4 Safety Cover - Open / Close - Button............................................... 205
9.5.5 Safety Cover - Safety Switch..................................................... 207
9.5.6 Safety Cover - Closing Force..................................................... 210
9.5.7 Safety Cover - Safety when Lowering...............................................212
9.5.8 Motors..................................................................... 214
9.5.9 Pneumatic.................................................................. 219
9.5.10 Conveyor Belt................................................................221
9.5.11 Power Sockets............................................................... 223
9.6 MAINTENANCE SHEET - CHECK MACHINE .....................................225
9.7 MAINTENANCE SHEET - SURFACE CLEANING AND PREVENTION .................226
9.8 MAINTENANCE SHEET - LUBRICATE GUIDE RAIL(S) ............................. 232
9.9 MAINTENANCE SHEET - CLEANING THE CUTTER BLOCKS ........................234
9.10 MAINTENANCE SHEET - EXCHANGING BLADE ................................. 236
9.11 MAINTENANCE SHEET - EXCHANGE FEEDING BELTS ............................242
9.12 MAINTENANCE SHEET - PNEUMATICS - DRAIN CONDENSATION ..................244
9.13 MAINTENANCE SHEET - PNEUMATICS - CLEAN / REPLACE FILTER .................246
9.14 MAINTENANCE SHEET - CONTROL CABINET - CHECK FILTER .....................250

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9.15 MAINTENANCE SHEET - CHECK CONVEYOR BELT ...............................253
10 SPARE PARTS 254
11 DECOMMISSIONING / DISPOSAL 255
11.1 DECOMMISSIONING ........................................................255
11.2 DISASSEMBLY / DISPOSAL ...................................................256
12 OVERVIEW OF SYMBOLS 257
13 LIST OF FIGURES 261
14 PERSONAL NOTES 264
15 ADDITIONAL DOCUMENTS 266
16 WIRING DIAGRAMS 267
INDEX 259

1. General
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Original Operating Manual | Edition 1.0 (01-2020) | CrimpCenter 64 SP
GENERAL
Thank you for your trust in Schleuniger technology! You have acquired a high performance
product from Schleuniger, carefully designed and manufactured in our factory. 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 VALIDITY
This manual is valid for the following machine/s :
Base machine (article number 467 918)
1.3 MANUFACTURING DATE/PRODUCT TYPE
See „Rating Plate“.
1.4 INFORMATION ABOUT THE OPERATING INSTRUCTIONS
We have taken every possible measures to ensure the accuracy and completeness of this
documentation. 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 operate 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 safe-
ty regulations 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. General
Original Operating Manual | Edition 1.0 (01-2020) | CrimpCenter 64 SP 9 | 268
1.4.1 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:
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 "2.1.1 Personnel classication (Page 15)".
Operating Manual - EASY User Software
A detailed Operating Manual for the operation of the user software CrimpCenter 64 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 "2.1.1 Personnel classication (Page 15)".
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 "2.1.1 Personnel classication (Page 15)".
1.4.2 Depository
Keep the operating instructions as close as possible to the product and protected
against immissions.
The operating instructions must be available for the operating personnel at all times.
The contents must remain clearly legible beyond the expected lifespan of the product.
1.4.3 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. General
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1.5 GENERAL SYMBOLS AND LEGEND
1.5.1 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
Info Information which helps to operate the product eciently and
error-free.
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.
1.5.2 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.
"1.5.2 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.