Schleuniger ACO 08 User manual

ACO 08
Crimp Force M
onitor
Operating manual
Edition 1.00 (08-
2020)

Addresses / Representations
2 | 52 Operating Manual | Edition 1.00 (08-2020) | ACO 08
Schleuniger GmbH
Raiffeisenstrasse 14
42477 Radevormwald
Germany
P [phone]
F [phone]
[email protected]
www.schleuniger.com
Schleuniger, Inc.
87 Colin Drive
Manchester, NH 03103
USA
P [phone]
F [phone]
[email protected]
www.schleuniger
-na.com
Schleuniger AG
Bierigutstrasse 9
3608 Thun
Switzerland
P [phone]
F [phone]
[email protected]
www.schleuniger.com
Schleuniger Japan Co., Ltd.
4
-5-8, Tokai, Ota-ku
Tokyo 143
-0001
Japan
P [phone]
F [phone]
[email protected]
www.schleuniger.co.jp
Schleuniger AG
Business Unit Solutions
Gewerbestrasse 14
6314 Unteraegeri
Switzerland
P [phone]
F [phone]
[e-mail]
www.schleuniger.ch
Schleuniger Trading (Shanghai) Co., Ltd.
315, Yixiang Building
1599, West Yan‘an Road
Shanghai, 200050, China
P [phone]
77
F [phone]
[email protected]
www.schleuniger.cn

TABLE OF CONTENTS
1General...................................................................................................................................... 6
1.1 Dealer................................................................................................................................................................... 6
1.2 Year of manufacture / device type............................................................................................................ 6
1.3 Information about the operating manual.............................................................................................. 6
1.3.1 Content of the manual.................................................................................................................... 6
1.3.2 Storage location ................................................................................................................................ 7
1.3.3 Responsibilities.................................................................................................................................. 7
1.4 General symbols and keys............................................................................................................................ 7
1.4.1 Recommendations and tips.......................................................................................................... 7
1.4.2 Key.......................................................................................................................................................... 8
1.5 Declaration of conformity ............................................................................................................................ 8
1.6 Limitation of liability ...................................................................................................................................... 8
1.7 Warranty conditions....................................................................................................................................... 8
1.8 Copyright protection ..................................................................................................................................... 8
1.9 Privacy protection........................................................................................................................................... 9
1.10 Spare Parts ......................................................................................................................................................... 9
2Safety ......................................................................................................................................10
2.1 Warnings...........................................................................................................................................................10
2.2 General safety advice...................................................................................................................................10
2.3 Sources of danger / residual dangers.....................................................................................................10
2.4 Proper and intended use............................................................................................................................11
2.5 Safety symbols used.....................................................................................................................................11
2.5.1 Safety symbols used in the manual..........................................................................................11
2.6 Modification and conversion to the product......................................................................................12
2.7 Personnel qualifications..............................................................................................................................12
2.7.1 Personnel groups............................................................................................................................12
2.8 Personal protective equipment ...............................................................................................................13
2.8.1 Goggles...............................................................................................................................................13
2.8.2 Protective work clothing..............................................................................................................13
2.9 Safety equipment..........................................................................................................................................13
3Transport / Packaging / Storage............................................................................................ 14
3.1 Transportation inspection..........................................................................................................................14

Addresses / Representations
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3.2 Unpacking / unloading................................................................................................................................14
3.3 Packaging.........................................................................................................................................................14
3.3.1 About the packaging.....................................................................................................................14
3.3.2 Handling the packaging materials ...........................................................................................14
3.4 Shipping............................................................................................................................................................14
4Product Specifications ...........................................................................................................15
4.1 Dimensions and weight..............................................................................................................................15
4.2 Technical key data.........................................................................................................................................15
4.3 Setup location.................................................................................................................................................16
4.4 Rating plate .....................................................................................................................................................16
5Product Description ...............................................................................................................17
5.1 Concept.............................................................................................................................................................17
5.2 Front view ........................................................................................................................................................18
5.3 Rear view ..........................................................................................................................................................19
5.4 Control elements and interfaces..............................................................................................................19
5.5 Scope of delivery ...........................................................................................................................................20
5.6 Accessories ......................................................................................................................................................20
6Installation.............................................................................................................................. 21
6.1 Installation .......................................................................................................................................................21
6.1.1 Remove the ACO 08 and the accessories from the packaging.......................................21
6.1.2 Place the device at its final location.........................................................................................21
6.1.3 Install the crimping machine-specific cable kit and connect it with the ACO 08....21
6.2 Commissioning ..............................................................................................................................................21
7General Handling / Operation ............................................................................................... 22
7.1 General operating information ................................................................................................................22
7.2 User interface..................................................................................................................................................22
7.2.1 Main menu ........................................................................................................................................22
7.2.2 Monitoring mode............................................................................................................................23
7.2.3 Teaching.............................................................................................................................................26
7.2.4 Setup ...................................................................................................................................................27
7.2.5 User levels..........................................................................................................................................31
7.2.6 Job management............................................................................................................................33
7.2.7 Information dialog..........................................................................................................................36
7.2.8 Automatic parametrization.........................................................................................................37

General
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7.2.9 Headroom test .................................................................................................................................38
7.2.10 Machine profiles..............................................................................................................................40
8Diagnosis / Troubleshooting ................................................................................................. 41
8.1 What to do in the event of problems.....................................................................................................41
8.2 Possible machine faults...............................................................................................................................41
9Maintenance ...........................................................................................................................43
10 Disposal................................................................................................................................... 44
10.1 Decommissioning .........................................................................................................................................44
10.2 Disassembly / disposal ................................................................................................................................44
11 Parts Catalog ..........................................................................................................................45
11.1 Spare parts .......................................................................................................................................................45
12 Exploded Drawings ................................................................................................................46
13 Block Diagram ........................................................................................................................47
14 PLC Interface........................................................................................................................... 48
15 Notes ....................................................................................................................................... 50
16 Index........................................................................................................................................ 51

General
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1GENERAL
Thank you for choosing Schleuniger technology. You have purchased a high-performance
Schleuniger product that has been developed with care and manufactured in cooperation with our
partner, KMF Messtechnik. Carefully read this operating manual. It contains important tips and
safety instructions to ensure efficient, precise and reliable production of cables.
1.1 DEALER
In this Operating Manual Schleuniger GmbH, Deutschland, is designated as dealer and abbreviated
to
“Schleuniger” .
Schleuniger GmbH Phone: [phone]
Raiffeisenstrasse 14 Fax: [phone]
42477 Radevormwald Email:
[e-mail]
Germany Web: http://www.schleuniger.de
1.2 YEAR OF MANUFACTURE / DEVICE TYPE
Refer to the “EC declaration of conformity (register 2)” of the folder.
1.3 INFORMATION ABOUT THE OPERATING MANUAL
■The operating manual is a part of the product and contains all relevant information for using the
product efficiently and safely in accordance with its intended use.
■The safety advice and other instructions given must be adhered to, in addition to the applicable
local accident prevention regulations and general safety regulations for the area of application.
■If the product changes ownership, the operating manual must also be passed on to the new
owner.
■It is important to ensure that any available safety-related changes or corrections can be
included in the operating manual. For more information, contact your local
Schleuniger
representative
1.3.1 Content of the manual
Each person who works with the product must be sufficiently trained and, before starting work,
must have read and understood the operating manual. This is also applicable if the respective
person has already worked with the product or a similar one or has been trained by the
manufacturer.
The operating manual becomes invalid if contents are removed (excluding the quick reference, if
present), or contents on the data carrier are altered.
We are committed to making it as simple as possible to use our products, to reference information
and to instruct new employees, which is why we divide our operating manuals into four clearly
structured chapters:
■Operating
■Maintenance
■Repairs
■Parts catalog

General
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1.3.2 Storage location
The operating manual must be accessible to the operating personnel at the workplace at all times.
Select a storage location where the operating manual cannot be damaged, so that the manual
remains clearly legible over the expected service life of the product.
1.3.3 Responsibilities
■This operating manual must be stored in the immediate vicinity of the product. It must be kept
accessible to personnel who work on or with the product at all times.
■Completely and unreservedly observe the information given in the operating manual.
1.4 GENERAL SYMBOLS AND KEYS
1.4.1 Recommendations and tips
The meanings of the following symbols in the operating manual are as follows:
Tip:
Recommendations and tips for
easier operation of the product in
accordance with the intended use.
Info:
Important information for efficient,
trouble-free operation.
Magnifying glass:
Important chart, introductory
chapter.
Menu level:
Sub-screen with menu level (starting
from main menu).
Procedure:
Important instruction, programming
sample.
Figure reference:
Text reference to elements in a
preceding figure.
Content reference (topic):
Important safety-related content
reference.
Disposal:
Waste material that must be recycled
and not disposed of in domestic
waste.

General
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1.4.2 Key
Markups with the following meaning are used in the text.
Markup Meaning Description
[SWITCH] Switch / Button Key commands and buttons from screen
presentations are depicted in square brackets,
italics and orange.
“Configuration”Screen titles /
menus
Screen titles and menus are depicted in quotation
marks.
Schleuniger Product names and
company
Product and company names are depicted in
italics.
“1.5 Key (Page 9)” Cross reference Cross references are depicted in blue and italics.
1.» Instruction Instructions are enumerations with arrow.
➥Results of an
instruction
Explanations and actions initiated in instructions
are indicated by an arrow.
The following abbreviations are used.
Abbreviation Meaning Description
Fig. Figure Images are referred to in the captions as Figure.
mm Millimeters All dimensions in this manual are given in
millimeters.
1.5 DECLARATION OF CONFORMITY
See appendix.
1.6 LIMITATION OF LIABILITY
This manual was compiled while taking into account the applicable norms and guidelines, state-of-
the-art technology and our many years of experience.
The manufacturer accepts no liability for any damages or accidents resulting from:
■Disregard of the manual
■Disregard of the safety signs
■Improper use
1.7 WARRANTY CONDITIONS
See the Schleuniger document, “General Terms of Sale and Delivery” .
1.8 COPYRIGHT PROTECTION
This operating manual must be treated confidentially. It is only intended for persons who are
involved in work with the product. The operating manual must not be made available to third
parties without the express written consent of the manufacturer.

General
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The manufacturer holds the copyright to the contents of the operating manual (text, figures,
illustrations, drawings, diagrams and other representations).
1.9 PRIVACY PROTECTION
Schleuniger processes personal data in compliance with the Schleuniger privacy protection
declaration. This declaration is available in the following languages and addresses.
Language Address
German schleuniger.com/de/rechtsmittel-und-datenschutzerklärung
English schleuniger.com/en/legal-information-and-privacy-statement
Spanish schleuniger.com/na/es/información-legal-y-aviso-de-privacidad
Japanese
schleuniger.com/jp/jp/法的情報およびプライバシー宣言
Chinese
schleuniger.com/cn/cn/法律和隐私条款
1.10 SPARE PARTS
Original spare parts must always be purchased from your local Schleuniger representative.
We reserve the right to change the appearance or function of spare parts as part of product
improvement without prior notice.
Caution
Use of incorrect spare parts
Incorrect or faulty spare parts can lead to damage, malfunction or total failure of the
product as well as affecting the safety of the operating personnel. Therefore, use
only original spare parts from Schleuniger .

Safety
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2SAFETY
2.1 WARNINGS
Throughout the operating manual, warnings are indicated by the following symbols. They are
introduced by danger signs and key words which indicate the extent of danger. The warnings must
be adhered to in order to prevent accidents, personal injury and tangible damage.
Danger
“Danger”
This indicates an imminent hazardous situation, that will result in death or serious
injuries if it is not avoided.
Warning
“Warning”
This indicates a potential hazardous situation, that can result in death or serious
injuries if it is not prevented.
Caution
“Caution”
This indicates a potential hazardous situation, that can result in moderate or light
injuries if it is not avoided.
Notice
“Tangible damage”
This indicates a potential hazardous situation, that can result in material damage if
it is not avoided.
2.2 GENERAL SAFETY ADVICE
■The product must only be operated in a fully serviceable and safe operating condition. Before
starting the product, check that it is serviceable.
■Never operate the product in environments where there is a risk of fire or explosion.
■Only operate the product in dry, dust-free surroundings.
■Disconnect the product from the electrical power supply and/or the compressed air supply
before performing any maintenance or repair work.
■Only use original Schleuniger accessories, especially interface cables (electromagnetic
compatibility).
2.3 SOURCES OF DANGER / RESIDUAL DANGERS
There are hazards involved when using technical products.

Safety
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Any hazards that cannot be eliminated by design measures or protective devices are considered to
be residual hazards. The safety information in this operating manual indicate known residual
hazards. If other dangers become apparent during operation, then the operating company must
inform
Schleuniger of these immediately.
Under some circumstances, the following residual hazards can occur:
■Injuries and faults on the product can occur due to inadequate maintenance of the product.
■Danger of tripping, falling and slipping caused by connection cables, compressed air hoses and
wire residues on the floor.
■Injuries may happen when working at the workplace without adequate lighting.
2.4 PROPER AND INTENDED USE
Notice
Use the product only as intended!
Each use of the product which contradicts the intended use is considered as
improper. Schleuniger accepts no liability for damages as a result of improper use.
Caution
Intended use
The product has been designed and built exclusively for the intended use specified
below:
The ACO 08 is used for monitoring and analyzing the crimping process within the
range according to the technical data.
Nonadherence can lead to injury to the operating personnel and material damage.
Caution
Reasonably expected misuse
Do not use the product for the following tasks:
■Monitoring/analyzing force values on machines not intended for this task
Non-adherence can lead to injury to the operating personnel and material damage.
2.5 SAFETY SYMBOLS USED
2.5.1 Safety symbols used in the manual
Safety symbols are used in this manual to warn the operator of possible dangers. These are
described in detail below.
General
danger!
Hints and instructions marked with this symbol must be strictly
followed. Disregard can lead to injuries and material damage.
Electrical
current!
There is a danger of electric shock at the power connector and
inside the machine. This means that you must always switch off
the machine at the main switch and disconnect it from the
mains power supply before opening. Users may injure
themselves if they come in contact with live components.

Safety
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2.6 MODIFICATION TO AND CONVERSION OF THE PRODUCT
In order to avoid possible dangers and guarantee optimal performance, modifications, additions
and conversions on the product are not permitted without the express written consent of the
manufacturer or the
Schleuniger representative. This does not include official equipment options
and accessories offered by
Schleuniger .
2.7 PERSONNEL QUALIFICATIONS
The various tasks may only be carried out by the personnel specified in the corresponding
chapters.
The product has been designed for use by persons over the age of 14. Allowing access to younger
persons is strictly forbidden.
Caution
Potential risk due to inadequate qualification!
Users may become injured when handling the product improperly.
There are hazard areas that require special caution. The product may only be
operated by the groups of persons mentioned in the respective chapter.
2.7.1 Personnel groups
The following qualifications are specified in the manual for the various tasks.
2.7.1.1 Operating company
As a supervisory legal authority, the operating company is responsible for using the product as
intended as well as for the training and employment of the authorized persons. The operating
company specifies the binding competencies and authorities of the authorized personnel.
2.7.1.2 Technical specialists
Based on their product-specific training as well as their initial mechanical and electrical training
and their experience, they are able to carry out the maintenance and repair work on the product as
commissioned.
2.7.1.3 Technical personnel
Based on their technical skills, professional experience and product-specific training, they are able
to install the product, to commission it and to instruct the operating personnel.
2.7.1.4 Operating personnel
Persons who have been instructed and authorized by the operating company to operate the
product in a safe manner in accordance with the regulations. They are able to detect and avoid
possible hazards. This also includes knowledge of accident prevention regulations and first aid.
2.7.1.5 Third parties
External personnel solicited the operating company, service technicians and employees from
Schleuniger .

Safety
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2.8 PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment in accordance with the local regulations is required when working
on the product to minimize possible health risks.
■Always wear the necessary protective equipment for the corresponding task.
■Observe the signs in the working area relating to personal protective equipment.
2.8.1 Goggles
For protecting the eyes against small parts generated when processing the product to be cut.
2.8.2 Protective work clothing
Wear close-fitting work clothing with low tear resistance and no protruding parts. Protects against
being caught by movable machine parts.
2.9 SAFETY EQUIPMENT
The safety equipment on the product (used for safety, protection and monitoring) must not be
removed, bridged, modified or bypassed. The safety equipment must be inspected on a regular
basis. Defective safety equipment must be repaired immediately. Only then can the product be put
back into operation.
■Never operate the product with the safety cover open.

Transport / Packaging / Storage
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3TRANSPORT / PACKAGING / STORAGE
The following instructions must be followed exactly when unpacking, transporting and storing the
product. They contain important information for preventing personal injury and damage to the
product. The weight of the product must be taken into account during transportation and loading.
See chapter
4.1 Dimensions and weight .
Notice
Personnel qualifications
The instructions listed in this chapter must be carried out by the technical personnel!
3.1 TRANSPORTATION INSPECTION
Check the delivery immediately for completeness and transport damages.
In the event of externally visible transport damages, proceed as follows:
■Do not accept the delivery, or only accept it conditionally.
■Define the extent of the damages.
■Report damages to the product immediately.
3.2 UNPACKING / UNLOADING
Caution
Transportation lock!
The product may be damaged if transportation locks are not removed prior to
operation.
Remove marked transportation locks before possibly planned commissioning of the
product (store transportation locks for future transport).
3.3 PACKAGING
3.3.1 About the packaging
Keep the packaging materials in weatherproof storage for later transportation.
3.3.2 Handling the packaging materials
Recycle any packaging no longer needed.
See chapter
10 Disposal .
3.4 SHIPPING
Use the associated packaging before shipping the device. Disconnect all connected cables from
the device.

Product specifications
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4PRODUCT SPECIFICATIONS
Among others, this chapter gives an overview of the technical data of the product. The technical
data corresponds to the theoretical values that can be achieved under normal conditions. We
reserve the right to change the technical data and design as part of product improvement without
prior notice.
4.1 DIMENSIONS AND WEIGHT
Fig. 1: Dimensions
Description Value Swivel in the unit
Weight 0.5 kg
Dimensions Width (A) 134 mm
Depth (B) 41 mm
Height (C) 96 mm
4.2 TECHNICAL KEY DATA
Description Value Swivel in the unit
Ambient conditions Temperature range (operation) +0 to +50 °C
Temperature range (storage) +0 to +50 °C
Relative humidity at 20 °C 90 %
Relative humidity at 40 °C 50 %
Protection class IP 20
Limit values, incl. measuring range 0 – 20000 N
Units N, lb, without
Channels 2
Data capacity 8 GB (µSD)
Sensor type Piezo and DMS
Interfaces Ethernet, USB,

Product specifications
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Description Value Swivel in the unit
Digital IO
Trigger external, internal
Feed connection Operating voltage 12 – 24 VDC
Power consumption (max.) 10 W
4.3 SETUP LOCATION
Set up on hard nonfragile surface or mount to the crimping machine.
4.4 RATING PLATE
To ensure our efficient support, we request the customer to always submit the exact content of the
rating plate when contacting us with requests.
The rating plate is located on the side wall and contains the following specifications.
1 Product 4 Permissible operating voltages
2 Serial number 5 Internal fuses
3 Year of manufacture 6 Manufacturer
1
2
6
3
4
5

Product description
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5PRODUCT DESCRIPTION
The product description chapter gives the performance description, information on the product
limits and the scope of delivery. The individual operating elements on the product are indicated
and described using photos. Additionally, the product description also contains information on
operating modes and functionality.
5.1 CONCEPT
The ACO 08 crimp force monitoring monitors and analyzes the crimping process. The device can be
used to evaluate and optimize the crimping processes in the sector of further development of
crimping technology, as well as for monitoring, control, and checking the production process.
A series of adjustable parameters for the device, as well as the simple operation of the device,
permit adaptation to different crimping uses.
A piezoelectric force sensor generates a load (proportional to the crimp force) and supplies
measuring signals. The sensor is located within the crimping press and converts crimp force
coefficients into load coefficients which can then be evaluated by the measuring device. The
process-controlled measuring device conducts an analog-to-digital data conversion and saves
these coefficients in the internal log memories.
To control the crimping process, a reference force coefficient is calculated by recording and
averaging a certain number of crimp force coefficients. Based on this force curve, an envelope is
generated which can be modified by the user according to the specific requirements of the
crimping process. In addition, the area under the curve (work) is calculated as a reference value.
The crimping process itself is monitored to prevent exceeding the tolerance limits or deviation
from work within a certain part of the tolerance range. The comparison of the reference and actual
values generates a digital control signal that allows the crimp machine to be directly connected.
This allows the machine to be blocked and the crimped parts to be sorted out. Event counters
(crimp good/bad/total/Cpk) are continuously updated on the screen. The actual process
parameters can be displayed at any time.
The measured force parameters can be transmitted via TCP/IP to a connected PC, where a software
package generates a graphical representation. The PC software enables the storage of all
generated data as well as various statistical and conversion functions. All independent data (e.g. for
printouts) can be downloaded to the PC. The measuring instruments can be networked.

Product description
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5.2 FRONT VIEW
Fig. 2: Control elements
1 Touch display with graphical user Interface
1

Product description
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5.3 REAR VIEW
Fig. 3: Rear view
1 Mounting device with ball head 5 TCP/IP interface
2 Rating plate 6 USB interface
3 Sensor cable connections (channels 1 and 2) 7 Digital IO interface
4 Mains socket for external mains supply
5.4 CONTROL ELEMENTS AND INTERFACES
Touch display
The ACO 08 does not have any physical switches. All inputs are made via gestures or digital buttons
on the graphical user interface.
Sensor cable connections (channels 1 and 2)
Input sockets for the signal of the force sensors. The right socket is to be used if only one channel is
used.
Mains socket for external mains supply
An external power supply can be connected if the ACO 08 cannot be supplied with power via the
crimping machine.
TCP/IP interface
Allows integration of the device into a network and transmission of data to a PC.
1
2
3
4
5
6
7

Product description
20 | 52 Operating Manual | Edition 1.00 (08-2020) | ACO 08
USB Interface
Enables service functions such as firmware updates or reading data
Digital IO interface
Enables the output and receipt of control signals between ACO 08 and crimping machine
5.5 SCOPE OF DELIVERY
See goods data sheet.
5.6 ACCESSORIES
Please use only original manufacturer accessories.