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Continental Refrigerator
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PC440i Series
Operator's Manual
62 pgs10.69 Mb0

Continental Refrigerator PC440i Series Operator's Manual

Group or Division Here
Industrial Fluid Solutions
PC440i Crimper
with CrimpIQ™ Controller
Operator Manual
www.contitech.us
www.contitech.us
2 PC440i Crimper – Operator Manual
Table of Contents
PC440i Series ............................................................................................................................................................................................................................................................................................................................................................ 7
Operational Information .......................................................................................................................................................................................................................................................................................................... 30
Table of Contents
PC440i Crimper with CrimpIQ™ Controller
Machine Coniguration ..............................................................................................................................................................................................................................................................................................................36
Default User Accounts ............................................................................................................................................................................................................................................................................................................... 38
Maintenance Mode ........................................................................................................................................................................................................................................................................................................................ 39
Adapter Die Installation ..............................................................................................................................................................................................................................................................................................................51
Hydraulic Die Installation ......................................................................................................................................................................................................................................................................................................... 52
Resetting the PLC to Its Original Settings ........................................................................................................................................................................................................................................................... 53
CustomCrimp® “No Nonsense” Warranty ............................................................................................................................................................................................................................................................61
3PC440i Crimper – Operator Manual
Table of Contents
PC440i Crimper with CrimpIQ™ Controller
4 PC440i Crimper – Operator Manual
SAFETY PRECAUTIONS
• Read instructions and identify all component parts before using the crimper.
i
• PC440i crimper can produce 265 tons of crimping force.
• Keep both hands away from pinch points.
• Consult the Continental Crimp Speciications Manual for correct crimper setting and crimp measurements.
• Always wear eye protection.
PC440i Safety Precautions
PC440i Crimper with CrimpIQ™ Controller
PC440i Initial Crimper Setup
Hydraulic Oil Check: Check the hydraulic oil level in the sight
glass window on the front of the reservoir.
Notes:
• The reservoir requires 8 gallons of ISO grade 46 hydraulic oil for complete ill.
• If necessary, oil can be drained from either of the two ports at the bottom of the reservoir.
Voltage Tag Check: Check electrical circuit to be certain that
it matches the crimper’s requirements shown on the voltage tag attached to the crimper cord.
5PC440i Crimper – Operator Manual
Notes:
• Plug the PC440i crimper directly into the appropriate electrical circuit/wall outlet.
• Electrical Requirements:
7.5HP/230V/3Phase (20 Amp)
7.5HP/440V480V/3Phase (20 Amp) 5HP/230V/1Phase (30 Amp)
Caution: Do not run the crimper on an extension cord as low voltage
can damage the motor and/or electrical components.
Rotation of the Motor Check to be certain that the motor rotates Check: in the direction of the arrow shown on the
motor housing.
Caution: Damage to the pump can result if the motor does not rotate
in the correct direction.
PC440i Initial Crimper Setup
PC440i Crimper with CrimpIQ™ Controller
6 PC440i Crimper – Operator Manual
High-Level CrimpIQ™ Controller Capabilities
This version of the CrimpIQ™ controller is designed to take full advantage of the tablet interface and the connection to CrimpCloud®. CrimpCloud® is a web portal that provides users access to crimping and quality results captured in the
CrimpIQ™ controller.
CrimpIQ™ Supports the Following Features
Ease of Use:
• Quick access to simple hydraulic and industrial crimping modes.
• Optional semi and full automatic crimping modes.
• New touchscreen interface with clear, easy to read icon driven operations.
• Integrated measurement tools: Choice of USB wired or Bluetooth caliper provide direct measure input for crimp, diameters and industrial hose measurements.
• Integrated help and tutorial guides for easy feature reference.
• Ability to easily favorite crimp speciications, complete with notes, for easy reference and accurate repeat crimping.
• Ability to track and report on crimp measurements and crimp pressures.
Integrated Crimping Tools:
• Full integration with MyCrimp®, for easy importing and handling of full crimp speciications.
• Integrated Industrial Crimp Calculator computes appropriate crimp diameter based on hose and itting measurements.
• Support for foot pedal and electronic backstop.
Customizable:
• User account speciic settings, such as choice of millimeters or inches as irst choice for data entry.
• Create individual user logins (4-digit pins) to track usage and restrict machine coniguration.
Connected:
• Wi-Fi or Ethernet connections, for easy reference to manufacturer web content straight from the crimper, automatic coniguration backup and operations tracking.
• Ability to wirelessly update crimper software, providing up-to-date crimp speciications and new functionalities to crimper software.
• CrimpCloud® reporting to provide various reports on assemblies, crimps and machine maintenance.
Integrated Support and Maintenance:
• Simple on-crimper support ticket creation, with enhanced technical diagnostics for quicker and more responsive
help when needed most.
• Built-in tutorials and training, including feature tutorials on every screen.
• Dynamic machine maintenance tracking and reporting, showing historical tracking of maintenance.
• Preventive maintenance alerts avoid machine downtime and costly repairs.
• Detailed on-machine availability of machine capacities.
Expansion Options:
• Bluetooth 4.0 supports Bluetooth calipers and other approved accessories.
• 8GB on-device storage, for support of crimp speciications or other future applications.
High-Level CrimpIQ™ Controller Capabilities
PC440i Crimper with CrimpIQ™ Controller
PC440i Series
67"
Back Shelf
7.5 HP Motor High Capacity Pump
Electrical Enclosure
7PC440i Crimper – Operator Manual
Adjustable Mirror
CrimpIQ™ Controller
Emergency Stop
Audio and USB Ports
Crimper Head Open Button
Crimper Head Close Button
Adjustable Arm
Built-in Die Storage Pockets
Reservoir
46-½"
Small Footprint for Minimum Use of Space
99P Die Series
Foot Pedal for Use in Semi and Full Automatic Mode
52"
PC440i Speciications
Crimping force: 265 Ton
Hose capacity: Max 2SP: 2", 4SP: 2", 6SP: 1-½", Industrial: 4"
Size: L: 46-½" x W: 52" x H: 67"
Weight: 1,840 lbs.
Power: 7.5HP/230V/3Phase (Standard) 7.5HP/440V­480V/3Phase (Optional) 5HP/230V/1Phase (Optional)
Hydraulic die series: 99P
Adapter die series: 160MM to 99MM
Industrial die series: 160S
Adjustability: Inch/Metric
Opening w/o dies: 248mm/9.75"
Master die inside diameter: 160mm/6.3"
Master die travel: 102mm/4"
Reservoir capacity: 8 U.S. Gallons
Oil type: ISO 46 Hydraulic Oil
PC440i Series
PC440i Crimper with CrimpIQ™ Controller
8 PC440i Crimper – Operator Manual
PC440i Features
Continental CrimpIQ™ controller, the future of crimping at your ingertips.
Quickly Interchangeable Adapter Dies.
10-inch color capacitive touchscreen and user- friendly navigation.
Quick change tool makes die changes a quick and simple process.
Intuitive screens lead the operator through the setup and crimping process.
Fixed 6 o’clock die position allows the operator to place the itting on bottom die and crimp.
Manual backstop makes hydraulic hose production crimping fast and accurate.
PC440i Features
PC440i Crimper with CrimpIQ™ Controller
Foot pedal for use in semi and full automatic mode.
Built-in die storage pockets keeps frequently used die sets readily available.
Initial Crimper Setup
Overview
Before the crimper can be used for the irst time, a brief setup process must be completed. This process sets some initial parameters, identiies this machine to the CrimpCloud® system and allows the user to conirm the Terms and Conditions for use of this machine.
This process only needs to be completed once when the machine is installed. After that, the machine will power up and be ready for use.
9PC440i Crimper – Operator Manual
Initial Crimper Setup
PC440i Crimper with CrimpIQ™ Controller
10 PC440i Crimper – Operator Manual
Crimper Operations
Logging In
To begin using the crimper, you must irst login.
The crimper supports multiple users to allow tracking of activities as well as restrict access to some coniguration type functions.
Default User Accounts
The system comes with 3 users already created: admin, machine owner and user. Additional accounts can be added if required using the machine coniguration menu.
Pin codes listed below are defaults, and they can be changed by machine owners in the user menu:
If you have conigured additional users, their names will appear in this list as well. Once you have logged in, you can begin using the crimper.
Admin: A private account for certiied technicians and engineering maintenance.
Machine This account is an admin level account intended for the local administration. Owner: It has full access to all settings and functions. Default pin code is 9876.
User: This account has the permissions and capabilities to perform crimping operations but
has limited access to settings and diagnostics/setup functions. Default pin code is 1234.
Note: The system will automatically log users out of the system after the machine is idle for 1 hour.
This feature can be disabled or conigured in the Machine Coniguration screen.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
11PC440i Crimper – Operator Manual
Navigating the CrimpIQ™ Controller
This section provides an introduction to the controller screens and functions that are common throughout the application.
Basic Application Guide
This section outlines basic functions within the app that are common throughout the application. The basic outline and functionality is common throughout the application.
The screen is divided into the following sections:
Top Menu: This area of the screen provides high-level application and controller information
and access to help and settings.
Main Screen: Main screen with information and functions related to this screen
(directly linked to the screen title).
Left Menu: Provides access to information and functions that need to be available from everywhere
within the application. Access this with the menu button or by “swiping” left to right from the left side of the screen.
Top Menu
Left Menu Access
Main Screen
Top Menu
The top menu includes a screen title, access to menus and information.
Back/Menu Screen Title Information/Help
Back/Menu: This allows you to return one screen back (when you reach the main menu,
it brings out the left slide-out menu).
Information/Help: This option brings up help information relevant to the speciic location within the app.
Other: There are a few other status indicators that may be helpful.
• Right section displays Wi-Fi strength, Bluetooth status and machine time.
Navigating the CrimpIQ™ Controller
PC440i Crimper with CrimpIQ™ Controller
12 PC440i Crimper – Operator Manual
Left Slide-Out Menu
The left slide-out menu is available from anywhere within the Crimp controller app. It can be accessed by pressing the Menu button (always on the lower left side) or by swiping left from the left side of the screen. Once opened, pressing anywhere on the right side of the screen (right of the left slide-out menu) will close the menu.
The left menu contains information and functions that could be used at any time within the application.
Left Slide-Out Menu Information
The left slide-out menu provides a quick status of the system. This information includes:
Die Name: Name of the die (if any) that is currently loaded in the machine.
Position: Position of the crimp head, relative to the die currently loaded.
Target Diameter: The crimp diameter target currently loaded into the machine.
This is the diameter the crimper will close to given the size of the dies loaded into the machine.
Previous Max Max pressure on the last successful crimp. Pressure:
Last Activity Sync:
The last time that the machine has synced with CrimpCloud®.
Left Slide-Out Menu Functions
The left slide-out menu provides functions that can be executed from anywhere at any time:
Sync Activity: Sync Activity sends the latest crimper activity up to CrimpCloud®. Last Activity Sync data and time
described above detail the last successful data sync.
Change Die Mode: This mode allows the user to position the head to change dies. The machine tracks which dies are
loaded and will update information according to which dies are loaded.
"User Name" Change user function. This button displays the currently logged in user and provides a function to
login as a dierent user.
Main Menu: Return to the main menu of the application.
Crimper Return to the crimper operations menu. Operations:
Technical Support: Bring up the technical support function.
Navigating the CrimpIQ™ Controller
PC440i Crimper with CrimpIQ™ Controller
Using the Main Menu
This screen provides the main functions of the crimper.
13PC440i Crimper – Operator Manual
CrimpIQ™ Controller Main Menu Screen Options
Begin Crimping:
This button brings up the functions to perform hydraulic and industrial hose crimping.
Favorites: The Favorites button provides users with direct access to favorited crimp speciications.
Setting and This button brings up all of the support, information, training manuals and coniguration options Support: available for this machine.
Using the Main Menu
PC440i Crimper with CrimpIQ™ Controller
14 PC440i Crimper – Operator Manual
Crimper Operations
Main Crimper Operations Screen
The crimper operations screen is the starting point for setting up a crimping operation.
Favorites: This function contains all of the crimp speciications that have been previously favorited.
Crimp to Diameter: This function allows the user to directly enter a crimp diameter. Once entered, the system
will recommend a die and allow the user to proceed to Crimp Operations.
MyCrimp® Industrial: This brings up an Industrial Crimp Calculator. This calculator can determine the crimper
setup based on the hose diameter or hose wall thickness.
Load Crimp Speciications
This function allows the user to retrieve and load a crimp speciication from MyCrimp®.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
MyCrimp® – Search Screen
Use the Hose Type, Coupling Type and Hose Size to ind the crimp speciications you need.
15PC440i Crimper – Operator Manual
Key Functions of MyCrimp®
Hose Type:
Drill down into a list of hose types.
Coupling Type: Drill down into a list of coupling types.
Hose Size: Drill down into the list of hose sizes.
Crimper: This is preset to the current crimper type and cannot be changed.
Favorite: Allows the user to favorite selections and view them at the top of the list.
Clear: The clear button and trash can icon clear previous selections and let the user
begin a new search.
Total Crimp Specs: Lists the total number of crimp speciications found that match the search criteria.
View Crimp Allows the user to view a list of matching crimp speciications. Speciications:
Return to controller: Allows the user to abort the MyCrimp® search and return to the controller.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
16 PC440i Crimper – Operator Manual
Once you ind the desired crimp speciication, View Crimp Speciications will allow users to review the matching crimp speciications.
MyCrimp® – Results Screen
This view provides a review of the hose and itting selected. Select “Begin Crimping” to begin crimping.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
From the detailed view, users can view the full details of the crimp speciications.
Users can return to the previous screen with the Back button in the upper left corner or by using the "More Options" menu in the upper right to “Export Speciication.” An Export Speciication button is also found below the speciication details.
17PC440i Crimper – Operator Manual
MyCrimp® – Crimp This Speciication
Selecting “Crimp This Speciication” will allow the user to conirm the crimp speciication details.
Managing Crimp Speciications
Begin Crimping: Select this option to have the controller conigure the crimper and allow the operation to load/
conirm the correct die is loaded.
Die Options: In special situations, the user may wish to use an alternative die. To accomplish this, select the
Die Options button to bring up a list of all dies conigured for this machine.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
18 PC440i Crimper – Operator Manual
Crimp Speciications with Special Handling Requirements
There are cases where the user has to perform additional steps in order to select the correct crimp speciication for the hose and itting combination. In these cases, MyCrimp® will prompt the user with additional information. Users can then take the appropriate actions.
Crimper Operations
PC440i Crimper with CrimpIQ™ Controller
Favoriting Crimp Speciications
The user can save frequently crimped speciications for easy access and repeated crimping.
19PC440i Crimper – Operator Manual
This brings up a list of all the favorites saved on this machine. This scrollable list can be sorted by date added (Recent), Favorite name (Name) or hose size.
Favoriting Crimp Speciications
PC440i Crimper with CrimpIQ™ Controller
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