© Panduit Corp. 2006
CP-871
PA25085A01
Rev. 00 3-2006
OPERATION MANUAL
Website: www.panduit.com
E-mail: cs@panduit.com
Technical Support:
888-506-5400, ext. 3255
Fax: (630) 759-7532
CP-871 OPERATION MANUAL
TABLE OF CONTENTS
SAFETY REGULATIONS ENGLISH...........................................................................4
A.
A1. Symbols........................................................................................................................4
Product description ......................................................................................................4
A2.
Responsibilities ............................................................................................................4
A3.
A4. Personal qualifications .................................................................................................4
A5. Danger areas................................................................................................................4
Safety requirements .....................................................................................................4
A6.
1. ABOUT THIS OPERATOR MANUAL.........................................................................5
1.1. Important Information ...................................................................................................5
1.1.1. Manufacturer and Contact Address ........................................................................................5
1.1.2. Target Market..........................................................................................................................5
1.1.3. Obligation to Read ..................................................................................................................5
1.1.4. Validity.....................................................................................................................................5
1.1.5. Contents and Purpose ............................................................................................................5
1.1.6. Location...................................................................................................................................5
1.1.7. Symbols ..................................................................................................................................6
1.1.7.1. Security Tags....................................................................................................................................... 6
1.1.7.2. Security Tag ........................................................................................................................................ 6
1.2. Product Description......................................................................................................7
1.2.1. Tag..........................................................................................................................................7
1.2.2. Application...............................................................................................................................7
1.2.3. Application Limits ....................................................................................................................7
1.2.4. Conformance...........................................................................................................................7
1.2.5. Danger Areas..........................................................................................................................8
Page: 1 of 30
1.2.6. Technical Data........................................................................................................................8
CP-871 OPERATION MANUAL
2. OPERATING ELEMENTS .......................................................................... .................9
2.1. Main Switch ..................................................................................................................9
2.2. Control Panel................................................................................................................9
2.2.1. Display ....................................................................................................................................9
2.2.2. Keyboard...............................................................................................................................10
2.3. Monitors, Menus.........................................................................................................10
3. OPERATION.................................................................... ..........................................11
3.1. Production ..................................................................................................................11
3.1.1. Display ..................................................................................................................................11
3.1.2. Activate Cycle .......................................................................................................................11
3.1.3. Settings .................................................................................................................................12
3.1.4. Menu Counters......................................................................................................................12
3.1.4.1. Reset Counter ................................................................................................................................... 13
3.1.4.2. Programming Batch........................................................................................................................... 13
3.1.4.3. Total Counter..................................................................................................................................... 13
3.1.5. Functions...............................................................................................................................14
3.1.5.1. Crimp Speed...................................................................................................................................... 14
3.1.5.2. Crimp Force....................................................................................................................................... 14
3.1.5.3. Pneumatic Valve (Option).................................................................................................................. 15
3.1.5.4. Split Cycle.......................................................................................................................................... 16
4. TOOL REPLACEMENT.............................................................................. .... ........ ...17
4.1. Roller Carrier ..............................................................................................................17
4.2. Contact guide plate ....................................................................................................18
4.3. Applicator Assembly...................................................................................................19
4.4. Setting the Crimp Height ............................................................................................20
5. CRIMP FORCE MONITORING ACO05 ....................................................................21
6.
ERROR MESSAGES.................................................................................................21
Page: 2 of 29
7.
7.1. Daily Maintenance......................................................................................................22
MAINTENANCE.........................................................................................................22
CP-871 OPERATION MANUAL
7.1.1. Cleaning Processing Room...................................................................................................22
7.2. Lubrication..................................................................................................................23
7.3. Machine Preparation ..................................................................................................23
7.4. Slide............................................................................................................................24
7.5. Tool Base Plate ..........................................................................................................24
8.
8.1. Setting Crimping Height at 135.788mm .....................................................................25
9.
9.1. Replace Main Fuse ....................................................................................................26
10. APPENDIX.............................................................................. ...................................27
10.1. EU-Safety Data Sheet KLÜBER ................................................................................27
SETTINGS .................................................................................................................25
REPAIRS ...................................................................................................................26
Page: 3 of 29
CP-871 OPERATION MANUAL
A.
SAFETY REGULATIONS ENGLISH
A1. Symbols
Please follow exactly the work and
processes marked with this pictogram.
Failure to do so may result in death or
severe injury.
Please follow exactly the work and
processes marked with this pictogram.
Failure to do so may lead to minor injuries
and to damage to the machine.
A2. Product description
The PANDUIT CP-871 is a crimping machine for the
processing of all terminal, disconnect and butt splice crimping
contacts up to a cross section of 6mm2 (AWG10). The CA800EZ and CA9 applicators can be fit in. The operator
interface consists of membrane keypad and a display.
Functions such as speed control, split cycle, pneumatic valve
control, and various counter functions are selectable over the
interface.
The CP-871 may only be used as described in the enclosed
operating manual. Any deviation of the operation mode,
additions and extensions must first be discussed with Panduit.
A3. Responsibilities
The machine operator is responsible for ensuring that every
employee who uses the P
in accordance with these operating instructions (initial
operation, operation, maintenance). The training of the
operating personnel must include the following:
ANDUIT CP-871 has received training
• Purpose of the machine (see section A2 Product
description).
• Danger areas (see section A4 Personal
qualifications).
• Safety instructions (see Default A6 Safety
requirements).
• Operating the machine in accordance with these
operating instructions.
A4. Personal qualifications
To ensure that all instructions are understood, training must
take place in the language of the operating personnel. This
means that the following personnel qualifications are
required:
Assembly, initial
operation,
instruction
Operation
Maintenance,
service
Technical specialist staff who have a
good command of English and/or
German as well as of the language of
the operating personnel.
Trained staff in accordance with A3
Responsibilities.
Technical specialist staff who have a
good command of English or German.
A5. Danger areas
•
The whole area of the processing space
underneath the Plexiglas cover
- Danger due to the Crimp process of
the applicator
- Danger from Crimp stroke
• The entire interior area of the machine
and the metal casing:
- Danger from electrical current
- Danger from mechanical moving parts
A6. Safety requirements
•
This machine has been designed in
accordance with the European Standard
EN294.
• The machine must only be operated in
rooms that are dry and free from dust.
• Never operate the machine without its
protective covers.
• Never work on the machine without
wearing eye protection.
• Disconnect the machine from the
electrical and/or compressed air supply
before carrying out any maintenance
work.
• Never operate the machine with the
mains earth disconnected.
• Do not make any modifications to the
machine and only utilise it for its
intended purpose according to
Paragraph A2 Product description. Other
applications are only permitted with the
written approval of the manufacturer.
The manufacturer will accept no liability
for damage resulting from the disregard
of this regulation.
• Never operate the machine without first
having read through and understood all
instructions.
• Repair work may only be carried out by
authorised persons who have been
specially trained for this work.
• Ensure if you work on the machine that
long hair is not worn loose, and do not
wear loose clothing or ornaments that
could become caught in the moving
parts of the machine.
• Only use the lubricant that was delivered
with this machine according to these
operating instructions.
Page: 4 of 29
CP-871 OPERATION MANUAL
1. ABOUT THIS OPERATOR MANUAL
Thank you for trusting the PANDUIT Technology.
With the PANDUIT CP-871, you have acquired a semi-automatic crimping machine for the
processing of all terminal, disconnect and butt splice crimping contacts up to a diameter of 6mm
(AWG 10).
1.1. Important Information
1.1.1. Manufacturer and Contact Address
See Cover Page
1.1.2. Target Market
Technical Specialists (Team Leader, fitter)
See Chapter A4 Personal qualifications on Page 4
2
1.1.3. Obligation to Read
As operator and user one is obliged to read and understand this Reference Manual before the
initial operation, especially the chapter on safety regulations. Your safety is at stake! Should there
be any questions or lack of clarity, please contact your local Panduit representative.
1.1.4. Validity
This User Manual is valid for the PANDUIT CP-871 only.
1.1.5. Contents and Purpose
This Reference Manual contains all relevant information regarding the assembly, function,
commissioning and operation of the CP-871.
This Reference Manual is part of the client documentation and void without the Operating Manual
and the Maintenance Manual.
1.1.6. Location
This Reference Manual must be available to the team leader / fitter at the working place.
Page: 5 of 29
CP-871 OPERATION MANUAL
1.1.7. Symbols
1.1.7.1. Security Tags
Please read the following security advice with the tagged warnings thoroughly to avoid possible
injuries or material damage.
This symbol warns of immediate danger that could lead to severe injuries or death.
This symbol warns of a possibly dangerous situation that could lead to serious injury or
death.
This symbol warns of a possibly dangerous situation that could lead to injury or material
damage.
This symbol points to important information with regards to usage. Disregard can lead to
malfunction.
1.1.7.2. Security Tag
• Danger moving parts
• Attention danger through electric power
• Attention, warning of dangerous area
Qualified Personnel Only
•
Page: 6 of 29
CP-871 OPERATION MANUAL
1.2. Product Description
1.2.1. Tag
The nameplate is situated on the left side of press and contains the following information:
Model:
Voltage information
230 VAC T 6A
50/60 Hz 255 VA
1.2.2. Application
The PANDUIT CP-871 may only be used for processing crimping contacts and cables, i.e. to
activate the applicators.
CP-871
: 110 VAC bis T10A
1.2.3. Application Limits
Enviromental Temperature:
Storage and Transport Temperature:
Relative humidity:
50% on 40°C
+5°C to +40°C
-25°C to +55°C
90% on 20°C
1.2.4. Conformance
The CP-871 conforms entirely with the CE and EMV guidelines (mechanic and electric security,
electromagnetic tolerance.)
Page: 7 of 29
CP-871 OPERATION MANUAL
1.2.5. Danger Areas
Danger through moving
parts in the working area
1.2.6. Technical Data
Force 3.7 Tons / (33 kN)
Power (0.75 KW)
2
Up to approx. AWG 10 / (6mm
Cross Section Range
thickness up to .039 in. / (1mm) length of the
crimping zone, up to .315 in. / (8mm)
Stroke
Shut Height
1.57 in. / (40 mm); Optional 1.18 in. / (30 mm)
5.345 in. / (135.788 mm)
Height Adjustment Range ± .0098 in. / (0.25 mm), in increments
Cycle Time Adjustable from 350ms to 1 s
Press Activation Foot Pedal
Noise Level < 70 dB (A)
Power Connector 115 VAC bis 230 VAC
Net Frequency 50/60 Hz
Capacity 255 VA
Dimensions [mm] (W x H x D) 13“ x 30“ x 16“ / (320 x 750 x 400 mm)
Weight 176 lbs. / (80 kg)
Dimensions in ( ) are metric
). Material
Page: 8 of 29
CP-871 OPERATION MANUAL
2. OPERATING ELEMENTS
2.1. Main Switch
The CP-871 has no main switch. The power supply is cut off by removing the power cord
from the machine or by using the emergency stop button.
Picture 2.1: Main Switch
2.2. Control Panel
Emergency-Stop Button
1234567891234567
1234567891234567
Picture 2.2: Control Panel with Keyboard
2.2.1. Display
1234567891234567
1234567891234567
Picture 2.3: Display
Display
Keyboard
LED Operational
Page: 9 of 29
2.2.2. Keyboard
Escape Key:
Leave the entry mask or the menus
CP-871 OPERATION MANUAL
Creeping Speed Key –Left:
Moves the machine with reduced
speed against the machining
direction
Enter Key:
Activate the entry mask or confirm
the entry
Minus Key:
Minimize the value in a input field or
scroll in the selection menu or in the
sub-menus.
Plus Key:
Increase value in the input field or
or scroll in the selection menu or in
the sub-menus.
Creeping Speed Key – Right:
Moves the machine with reduced
speed in the machining direction
Operational LED:
The LED indicates that the machine
is in the upper dead center and
ready for use.
2.3. Monitors, Menus
Main Menu
Selection menus
Menu Counters Menu Functions Menu Settings
Reset Counter
990900
Set Batch
000900
Total Counter
99090000
Counter: 999999
Batch: 009999
Menu:
Counters
Menu:
Functions
Menu:
Settings
Crimp Speed
100%
Crimp Force
ON/OFF
Pneumatic Valve
ON/OFF 220ms
Split Cycle
ON/OFF 120°
Split Cycle
Speed 75%
Password
####
Language
English
Contrast:
Setting
Endurance Test
000900
Page: 10 of 29
CP-871 OPERATION MANUAL
3. OPERATION
The user’s task is as follows:
• Installing the tools
• Installing and setting the contact roller/retooling the contact guide plate
• Programming the counter functions and settings
• Producing cable
The CP-871 may only be operated by trained personnel (PANDUIT personnel or
trained personnel at the user)
3.1. Production
Start the CP-871 by plugging the power cable and/or unlocking the emergency-stop
button.
3.1.1. Display
Entries may always be made once the prompt in the display flashes.
3.1.2. Activate Cycle
• The machine gets started with the foot pedal
Page: 11 of 29
3.1.3. Settings
Set the menu language
Counter: 999999
Batch: 009999
CP-871 OPERATION MANUAL
Main Menu
•
Menu:
Counters
Menu:
Settings
Password
####
Password
0###
Language
English
• , Selection menu „Counters“
• With 2 x change to „Settings“ in the menu
• With log into the sub-menu password
•
• Change the numerical value
• Repeat the procedure until all four figures have
• , Sub-Menu language setting (if the password
•
, Password entry is activated (the first figure
flashes) Password 0200.
or . Once the
wanted value is reached, confirm
figure flashes).
been entered
was incorrectly entered the sub-menu cannot be
accessed.
, Function Language setting gets activated.
With
English, French, Italian, Spanish)
or choose the language (German,
. (the second
Counter: 999999
Batch: 009999
3.1.4. Menu Counters
Counter: 999999
Batch: 009999
Menu:
Counters
Reset Counter
990900
•
• 2 x , back to main menu.
• Main menu
• , Selection menu „Counters“
• With change to menu „Counters“.
Page: 12 of 29
, Confirm language.
3.1.4.1. Reset Counter
CP-871 OPERATION MANUAL
Reset Counter
990900
Reset Counter
000000
Counter: 999999
Batch: 009999
3.1.4.2. Programming Batch
Set Batch
000900
Set Batch
002500
Counter: 999999
Batch: 009999
• , Activate „Reset Counter” (figures flash).
• , Reset Counter
• 2 x , back to the main menu or directly to
the submenu „Set Batch” with
• , Submenu „Set Batch“.
•
• With or Enter Batch.
•
• 2 x , back to main menu or directly to
, Activate function „Set Batch“.
, Confirm entry.
sub-menu „Total Counter“ with
.
Counter: 999999
Batch Processed
3.1.4.3. Total Counter
Total Counter
99090000
Counter: 999999
Batch: 009999
• Once the Batch is reached „Batch
Processed“ will appear. By pressing
new Batch is activated. To deactivate the
Batch function, programm a Batch value of
„000000“.
• 2 x , sub-menu „Total Counter”
(Information)
• 2 x , back to main menu. With into
sub-menu „Det Batch” or with 2x
sub-menu „Reset Counter”.
the
into
Page: 13 of 29
3.1.5. Functions
CP-871 OPERATION MANUAL
Counter: 999999
Batch: 009999
Menu:
Counters
Menu:
Functions
Crimp Speed
100%
3.1.5.1. Crimp Speed
Crimp Speed
100%
Crimp Speed
080%
• Main Menu
• , Selection menu „Counters“
• With go to menu „Functions“
• With go to sub-menu „Functions“.
• , „Crimp Speed“ function is activated
(figures are flashing).
With
•
pressing speed in percentage.
• 100% Ömax. speed Ö ca. 350ms
• 5% Ömin .speed Ö ca. 1s
and one can adjust the
Counter: 999999
Batch: 009999
3.1.5.2. Crimp Force
This feature does not function with PANDUIT product and is not supported by
PANDUIT.
•
• 2 x , back to main menu or with direct
, accept entry.
into the sub-menu „Crimp Force“ (Crimp
Force monitoring).
Page: 14 of 29
CP-871 OPERATION MANUAL
3.1.5.3. Pneumatic Valve (Option)
A badly set feeder timing may damage the machine. Always install pneumatic tools
without contact material, until the feeder timing is properly set.
Pneumatic Valve
OFF
Pneumatic Valve
ON 220ms
• 2 x , sub-menu „Pneumatic Valve“.
• With
, „Pneumatic Valve“ function is
activated (figures are flashing).
• With and activation of the „Pneumatic
Valve“ function and by pressing the
key
timing of the valve can be programmed.
•
, accept entry.
• The length of time the valve is engaged is
permanently programmed and can not be
changed..
Counter: 999999
Batch: 009999
2 x
•
directly into the sub-menu „Split Cycle“.
, back to the main menu or with go
• Connect the compressed air on the pressure
gauge.
• Assemble the tool according to Chapter 4.3
Applicator Assembly on page 19.
• Connect both pneumatic attachments at the
valve
• Switch on the air pressure unit using the main
switch at the pressure gauge.
• Set gage at 6 bar processing pressure
Page: 15 of 29
3.1.5.4. Split Cycle
Split Cycle
OFF
Split Cycle
ON 120°
Upper
dead
center
CP-871 OPERATION MANUAL
• 3 x , sub-menu „Split Cycle“.
•
• With and the „Split Cycle“ function
, „Split Cycle“ function is activated
(figures are flashing).
can be activated and by press the
the breakpoint can be programmed.
key,
• The „Split Cycle“ is used mainly for end
sleeve contacts, to centre the contact in the
Break
point
crimping stamp and to ensure easier
handling for the operator.
• Change to the sub-menu „Split Cycle Speed“
Split Cycle
Speed 75%
Split Cycle
Speed 45%
Counter: 999999
Batch: 009999
with
•
(figures are flashing).
• With and the pressing speed can be
adjusted in percent.The speed is
programmed from the upper dead center to
the breakpoint.
• 100% Ö max. Speed.
• 5% Ö min. Speed.
•
• 2 x , back to the main menu or with
back into the previous menu.
• Press the
(min. 3s)
.
, „Split Cycle Speed“ function is activated
, accept entry.
key to initialise the machine
Page: 16 of 29
CP-871 OPERATION MANUAL
4. TOOL REPLACEMENT
4.1. Roller Carrier
• Loosen both inner hexagon bolts of the pipe
clamp on the left side of the machine.
side
banded
• Turn the roller carrier 90° to the right for side
banded contacts.
• Set the height according to the contact roll.
• Tighten both hexagon bolts on the pipe
clamp.
• Attach the rear dead stop.
Assemble the contact roll.
•
• Set the braking power for the contact roll
using the forward dead stop and the spring.
Page: 17 of 29
CP-871 OPERATION MANUAL
4.2. Contact guide plate
• Loosen both of the knurled screws and lift
the sheet plate.
• Pull the sheet plate to the right and then
remove it.
Side
banded
• Assemble the sheet plate onto the distance
bolt at the left for side feed applicators.
• Attach the sheet plate using the knurled
screws.
• The contact material must be fed through the
black leading bracket
• Feed material into the applicator.
Page: 18 of 29
CP-871 OPERATION MANUAL
4.3. Applicator Assembly
• Open the front guard and remove the contact
material.
• Move the clamping lever on the left
downwards until the clamps are open.
• Assemble / disassemble the tool in the nut
and after remove at the bottom from the
retaining clamps of the applicator ground
plate.
• Move the clamping lever upwards until the
clamping fingers clamp the tool in their
respective grooves.
• Check that the tool is properly fastened and
close the protective cover.
• Set the tool according to the operating
guidelines set out by the manufacturer.
Page: 19 of 29
CP-871 OPERATION MANUAL
4.4. Setting the Crimp Height
The crimping height of the CA-800EZ and CA9 applicators can be adjusted within the
applicator. Further crimp height adjustments can be made to the press itself.
After each tool change, (before the first crimp), set the height of the machine to 0
Not doing so may damage the tool.
Only qualified personnel may carry out this setting.
Micro adjustment of the crimp height.
•
Turn the flange toothed surface.
•
• Minus direction, towards the left, increases
the crimping height. (e.g. 1.27 => 1.30).
• Plus direction, towards the right, decreases
the crimping height (e.g. 1.27 => 1.24).
• The setting is limited to ± 0.25 mm.
• The graduation is 0.025 mm per line.
• The reference point (135.788 mm) is marked
with the figure 0.
• Should the height setting not be used, this
function can be blocked by tightening the
inner hexagonal screw.
Page: 20 of 29
CP-871 OPERATION MANUAL
5. CRIMP FORCE MONITORING ACO05
This feature does not function with
PANDUIT.
PANDUIT
product and is not supported by
6. ERROR MESSAGES
Fault Action
Open Protection Cover
Machine not in Home Position
CFM not ready
• Connect protection cover to CP-871.
With the help of
•
Home Position. The green LED glows
• By activating the
menu (minimum 3x), the machine returns
to the home position. The machine
changes the turning direction
automatically as soon as it is in contact
with a resistor.
• Turn on CFM and check the connection of
the cable.
• Set the CFM to the production menu.
or return to
key in the main
• Disengage the emergency-off button or
No display on the monitor
plug into power.
• Check the fuse
Page: 21 of 29
CP-871 OPERATION MANUAL
7. MAINTENANCE
Activate the Emergency-Off button and separate the CP-871 from the power.
7.1. Daily Maintenance
• Clean the machine and the operating unit with a brush or a clean cloth
7.1.1. Cleaning Processing Room
• Open protection cover and
disassemble tool.
• Remove contact band residue,
cable and lubricating residue by
brushing and vacuum cleaning
inside the machine below the
wastage hole.
Page: 22 of 29
CP-871 OPERATION MANUAL
7.2. Lubrication
Lubricate the guide and all movable parts on the tool faceplate.
Lubricating interval: at least every 3 months
Lubricating Grease: Microlub GBU Y 131 (Will be delivered with the unit)
Use the lubricating grease delivered with the unit only according to the the
available instructions. Please note that the information relating to the lubricating
grease is given in the attachment to chapter 10 Appendix on page 27.
7.3. Machine Preparation
• Open protection cover.
Disassemble applicator.
Take machine down to the bottom
•
death centre with
• Open safety cover.
• Activate Emergency-Off button and
separate the machine from the
power supply system.
or keys
Press the Emergency-Off button and unplug the power supply. Lubricating work
may only be carried out by trained personnel (PANDUIT personnel or trained
personnel at the user)
Page: 23 of 29
7.4. Slide
CP-871 OPERATION MANUAL
A
7.5. Tool Base Plate
B
• Open safety cover
• Clean the slide’s guides (A / B) with
a lint free cloth.
• Lubricate the left guide (A) and the
right guide (B) on all three faces.
Clean the clamping claws of the
•
tool base plate with lint free cloth
and the delivered brush.
• Lightly lubricate the clamping claws
of the three bolts.
• Open and close the clamping claws
a few times
• Close safety cover
Deactivate Emergency-Off button and connect the machine to the power supply system.
•
• Bring the machine through operate
upper dead center.
key (min. 1x) in the main menu automatically into the
Page: 24 of 29
CP-871 OPERATION MANUAL
8. SETTINGS
8.1. Setting Crimping Height at 135.788mm
The crimping height may only be set by trained personnel (PANDUIT personnel
or trained personnel at the User) who have a SLM crimping height gage or a
similar device at their disposal.
• Set the height with help of the fine
adjustment on the crimping
machine until the display in the
window lies within the range of ±
005μ
• Turn the ring at the edged surface.
• Plus direction to the right, crimping
height increases (e.g. (1.27 =>
1.30)
• Minus direction to the left, crimping
height decreases (e.g. 1.27 =>
1.24)
• Now loosen the adhesives with the
scale and assemble them in such a
way that the reference
„0“corresponds again with the white
line.
Remove the limitation pin and
•
assemble into the hole above the
reference position. This will make
sure that the limitations are again
symmetrical.
• Remove the SLE CM gage. The machine is now set onto a crimp height of
135.788.
Page: 25 of 29
CP-871 OPERATION MANUAL
9. REPAIRS
Press the Emergency-Off button and unplug the CP-871’s power supply. Fuses
may only be replaced by trained personnel (PANDUIT personnel or trained
personnel at the user).
9.1. Replace Main Fuse
• Lift out the fuse holder with a screwdriver. Always replace both main fuses.
100/115 VAC = 2 x 10 A/T
230/240 VAC = 2 x 6 A/T
Lift Fuse holder
with a screw
driver
Fuses
Fuse holder
Picture 5.1: Replace main fuse
• Place the fuse holder back into the CP-871 and plug the line cord.
Page: 26 of 29
CP-871 OPERATION MANUAL
10. APPENDIX
10.1. EU-Safety Data Sheet KLÜBER
Page: 27 of 29
CP-871 OPERATION MANUAL
Page: 28 of 29
CP-871 OPERATION MANUAL
Index
A
Activate Cycle.......................................................11
Appendix...............................................................27
Applicator Assembly .............................................19
C
CFM not ready ..................................................21
Cleaning Processing Room ..................................22
Contact Lead ........................................................18
Control Panel......................................................... 9
Crimp Force..........................................................14
Crimp force monitoring..........................................21
Crimp Speed.........................................................14
D
Daily Maintenance ..........................................22, 23
Danger Areas ........................................................ 8
Display................................................................... 9
E
EU- safety Data Sheet KLÜBER...........................27
F
Functions..............................................................14
K
Keyboard ..............................................................10
L
Lubricating Grease:............................................23
M
Machine..............................................................21
Machine Preparation.............................................23
Main Switch............................................................ 9
Menu Counters .................................................... 12
Monitors, Menus .................................................. 10
N
No display on the monitor............................. 21
O
Open Protection Cover
P
Pneumatic Valve.................................................. 15
Programming Batch ............................................. 13
R
REPAIRS ............................................................. 26
Replace Main Fuse.............................................. 26
Reset Counter...................................................... 13
Roller Carrier........................................................ 17
S
Security Tag........................................................... 6
Security Tags......................................................... 6
Setting.................................................................. 25
Setting the Crimp Height...................................... 20
Settings................................................................ 12
Slide..................................................................... 24
Split Cycle............................................................ 16
T
Technical Data....................................................... 8
Tool Base Plate.................................................... 24
Total Counter ....................................................... 13
..................................... 21
Page: 29 of 29
© Panduit Corp. 2006
CP-871
PA25085A01
Rev. 00 3-2006
REFERENCE MANUAL
Website: www.panduit.com
E-mail: cs@panduit.com
Technical Support:
888-506-5400, ext. 3255
Fax: (630) 759-7532
CP-871 REFERENCE MANUAL
TABLE OF CONTENTS
A.
SAFETY REGULATIONS ENGLISH.........................................................................4
A1. Symbols......................................................................................................................4
A2. Product description .............................................................. .... .... ... ........ .... .... .... .......4
Responsibilities ..........................................................................................................4
A3.
Personal qualifications ......................... .... .... ........ .... .... .... ....... .... .... .... ........ .... .... .......4
A4.
A5. Danger areas........................................................................ ... .... ........ .... .... .... ........ ...4
A6. Safety requirements...................................................................................................4
1. ABOUT THIS OPERATOR MANUAL.......................................................................5
1.1. Important Information....................................... ............................................... ...........5
1.1.1. Manufacturer and Contact Address ......................................................................................5
1.1.2. Target Market........................................................................................................................5
1.1.3. Obligation to Read ................................................................................................................5
1.1.4. Validity...................................................................................................................................5
1.1.5. Contents and Purpose ..........................................................................................................5
1.1.6. Location.................................................................................................................................5
1.1.7. Symbols ................................................................................................................................6
1.1.7.1. Security Tags..................................................................................................................................... 6
1.1.7.2. Security Tag ................... ................................................................................................................... 6
1.2. Product Description................................................................................. ........ .... .... ...7
1.2.1. Tag........................................................................................................................................7
1.2.2. Application.............................................................................................................................7
1.2.3. Application Limits..................................................................................................................7
1.2.4. Conformance.........................................................................................................................7
1.2.5. Danger Areas........................................................................................................................8
1.2.6. Technical Data......................................................................................................................8
Page: 1 of 31
CP-871 REFERENCE MANUAL
2.
FUNCTIONS ..............................................................................................................9
2.1. Processing..................................................................................................................9
2.2. Crimping Connections................................................................................................9
3. CIRCUIT POINTS ....................................................................................................10
3.1. Overview ..................................................................................................................10
3.1.1. Crimp Force Monitoring (Optional)...................................................................................... 10
3.1.2. Pneumatic Valve (Optional) ................................................................................................10
3.1.3. FOOT PEDAL .....................................................................................................................10
3.1.4. Fuse Holder.........................................................................................................................10
3.1.5. Power Supply......................................................................................................................10
4. OPERATING ELEMENTS .......................................................................... .............11
4.1. Main Switch..............................................................................................................11
4.2. Control Panel............................................................ ............................................... .11
4.2.1. Display ................................................................................................................................12
4.2.2. Keyboard.............................................................................................................................12
5. MONITORS, MENUS...............................................................................................13
5.1. Main Menu................................................................................................................14
5.2. Settings ....................................................................................................................14
5.2.1. Menu language ...................................................................................................................14
5.2.2. Contrast Setting ..................................................................................................................15
5.2.3. Endurance Test...................................................................................................................16
5.3.
5.3.1. Reset Counter.....................................................................................................................17
5.3.2. Programming Batch ............................................................................................................17
5.3.2.1. Total Counter........................................ ........................................................................................... 18
Menu Counters..................................................... ............................................... .....17
5.4. Functions..................................................................................................................18
5.4.1. Crimp Speed.......................................................................................................................18
5.4.2. Crimp Force ........................................................................................................................18
Page: 2 of 31
5.4.3. Pneumatic Valve (Option)...................................................................................................19
5.4.4. Split Cycle...........................................................................................................................20
CP-871 REFERENCE MANUAL
6. TOOL REPLACEMENT.............................................................................. .... ........ .21
6.1. Roller Carrier.................................... .... .... ........ .... .... .... ........ ... .... .... ........ .... .... ........ .21
6.2. Contact guide plate ...................... .... .... ........ .... .... .... ........ .... .... .... ... ........ .... .... .... .....22
6.3. Applicator Assembly.................................................................................................23
6.4. Remove lateral cover .................................................................................. .............24
6.5.
Setting the Crimp Height..........................................................................................25
7. START-UP ...............................................................................................................26
7.1. Connect Compressed air ............................................. ............................................27
8. PRODUCTION.........................................................................................................28
8.1. Production start........................................................................................................28
9.
FAULT MESSAGES................................................................................................29
10. DISPOSAL...............................................................................................................30
10.1.
Packaging.................................................................................................................30
10.2. Machine........................................................................ ............................................30
Page: 3 of 31
CP-871 REFERENCE MANUAL
A.
SAFETY REGULATIONS ENGLISH
A1. Symbols
Please follow exactly the work and processes
marked with this pictogram. Failure to do so
may result in death or severe injury.
Please follow exactly the work and processes
marked with this pictogram. Failure to do so
may lead to minor injuries and to damage to
the machine.
A2. Product description
The PANDUIT CP-871 is a crimping machine for the processing
of all terminal, disconnect and butt splice crimping contacts up to
a cross section of 6mm2 (AWG10). The CA-800EZ and CA9
applicators can be fit in. The operator interface consists of
membrane keypad and a display. Functions such as speed
control, split cycle, pneumatic valve control, and various counter
functions are selectable over the interface.
The CP-871 may only be used as described in the enclosed
operating manual. Any deviation of the operation mode, additions
and extensions must first be discussed with Panduit.
A3.
The machine operator is responsible for ensuring that every
employee who uses the P
accordance with these operating instructions (initial operation,
operation, maintenance). The training of the operating personnel
must include the following:
Responsibilities
ANDUIT CP-871 has received training in
• Purpose of the machine (see section A2 Product
description).
• Danger areas (see section A4 Personal qualifications).
• Safety instructions (see Default A6 Safety
requirements).
•
Operating the machine in accordance with these
operating instructions.
A4. Personal qualifications
To ensure that all instructions are understood, training must take
place in the language of the operating personnel. This means
that the following personnel qualifications are required:
Assembly, initial
operation,
instruction
Operation
Maintenance,
service
Technical specialist staff who have a
good command of English and/or
German as well as of the language of the
operating personnel.
Trained staff in accordance with A3
Responsibilities.
Technical specialist staff who have a
good command of English or German.
A5. Danger areas
• The whole area of the processing space
underneath the Plexiglas cover
- Danger due to the crimp process of the
applicator
- Danger from crimp stroke
• The entire interior area of the machine and
the metal casing:
- Danger from electrical current
- Danger from mechanical moving parts
A6. Safety requirements
• This machine has been designed in
accordance with the European Standard
EN294.
• The machine must only be operated in rooms
that are dry and free from dust.
• Never operate the machine without its
protective covers.
• Never work on the machine without wearing
eye protection.
• Disconnect the machine from the electrical
and/or compressed air supply before carrying
out any maintenance work.
• Never operate the machine with the mains
earth disconnected.
• Do not make any modifications to the
machine and only utilise it for its intended
purpose according to Paragraph A2 Product
description. Other applications are only
permitted with the written approval of the
manufacturer. The manufacturer will accept
no liability for damage resulting from the
disregard of this regulation.
• Never operate the machine without first
having read through and understood all
instructions.
• Repair work may only be carried out by
authorised persons who have been specially
trained for this work.
• Ensure if you work on the machine that long
hair is not worn loose, and do not wear loose
clothing or ornaments that could become
caught in the moving parts of the machine.
• Only use the lubricant that was delivered with
this machine according to these operating
instructions.
Page: 4 of 31
CP-871 REFERENCE MANUAL
1. ABOUT THIS OPERATOR MANUAL
Thank you for trusting the PANDUIT Technology.
With the PANDUIT CP-871, you have acquired a semi-automatic crimping machine for
the processing of all terminal, disconnect and butt splice crimping contacts up to a
diameter of 6mm
1.1. Important Information
1.1.1. Manufacturer and Contact Address
See Cover Page
1.1.2. Target Market
Technical Specialists (Team Leader, fitter)
See Chapter A4 Personal qualifications on Page 4
2
(AWG 10).
1.1.3. Obligation to Read
As operator and user one is obliged to read and understand this Reference Manual
before the initial operation, especially the chapter on safety regulations. Your safety is at
stake! Should there be any questions or lack of clarity, please contact your local Panduit
representative.
1.1.4. Validity
This User Manual is valid for the PANDUIT CP-871 only.
1.1.5. Contents and Purpose
This Reference Manual contains all relevant information regarding the assembly,
function, commissioning and operation of the CP-871.
This Reference Manual is part of the client documentation and void without the Operating
Manual and the Maintenance Manual.
1.1.6. Location
This Reference Manual must be available to the team leader / fitter at the working place.
Page: 5 of 31
CP-871 REFERENCE MANUAL
1.1.7. Symbols
1.1.7.1. Security Tags
Please read the following security advice with the tagged warnings thoroughly to avoid
possible injuries or material damage.
This symbol warns of immediate danger that could lead to severe injuries or
death.
This symbol warns of a possibly dangerous situation that could lead to serious
injury or death.
This symbol warns of a possibly dangerous situation that could lead to injury or
material damage.
This symbol points to important information with regards to usage. Disregard can
lead to malfunction.
1.1.7.2. Security Tag
Danger moving parts
•
• Attention danger through electric power
• Attention, warning of dangerous area
Qualified Personnel Only
•
Page: 6 of 31
CP-871 REFERENCE MANUAL
1.2. Product Description
1.2.1. Tag
The nameplate is situated on the left side of press and contains the following information:
Model: CP-871
Voltage information
230 VAC T 6A
50/60 Hz 255 VA
1.2.2. Application
The PANDUIT CP-871 may only be used for processing crimping contacts and cables,
i.e. to activate the applicators.
: 110 VAC bis T10A
1.2.3. Application Limits
Enviromental Temperature:
Storage and Transport Temperature:
Relative humidity:
50% on 40°C
1.2.4. Conformance
The CP-871 conforms entirely with the CE and EMV guidelines (mechanic and electric
security, electromagnetic tolerance.)
+5°C to +40°C
-25°C to +55°C
90% on 20°C
Page: 7 of 31
CP-871 REFERENCE MANUAL
1.2.5. Danger Areas
Picture 1.2.5: Danger Areas
parts in the working area
Danger through moving
1.2.6. Technical Data
Force
Power
Cross Section Range
Stroke
Shut Height
Height Adjustment Range
Cycle Time
Press Acti va t i o n
Noise Level
Power Connector
Net Frequency
Capacity
Dimensions [in] (W x H x D)
Weight
Dimensions in ( ) are metric
3.7 Tons / (33 kN)
(0.75 KW)
2
Up to approx. AWG 10 / (6mm
to .039 in. / (1mm) length of the crimping zone, up to
.315 in. / (8mm)
1.57 in. / (40 mm); Optional 1.18 in. / (30 mm)
5.345 in. / (135.788 mm)
± .0098 in. / (0.25 mm), in increments
Adjustable from 350ms to 1 s
Foot Pedal
< 70 dB (A)
115 VAC bis 230 VAC
50/60 Hz
255 VA
13“ x 30“ x 16“ / (320 x 750 x 400 mm)
176 lbs. / (80 kg)
). Material thickness up
Page: 8 of 31
CP-871 REFERENCE MANUAL
2. FUNCTIONS
2.1. Processing
The stripped conductor is held in the connector.
Processing is activated with the foot pedal. The crimping press moves the tool down to
the lower dead center and thereafter to the upper dead center.
The tool separates the connector from the carrier strip, crimps the connector with the
conductor and feeds a new connector into position.
The carrier strip is cut by the applicator die.
2.2. Crimping Connections
The term crimping comes from the English word “to crimp” which means press, impress,
fold or fold deform.
In the electrical installation language, crimping means to mechanically fold or press the
connector onto the conductor.
Bare Connector
Stripped conductor Crimped Product
Page: 9 of 31
CP-871 REFERENCE MANUAL
3. CIRCUIT POINTS
3.1. Overview
1 2 3
4
5
1 Crimp Monitoring
2 Pneumatic Valve
3 Foot Pedal
Picture 3.1 Connections
4 Power Supply
5 Fuse Holder
3.1.1. Crimp Force Monitoring (Optional)
The crimp force monitor option does not work with PANDUIT product and is not
supported by PANDUIT.
3.1.2. Pneumatic Valve (Optional)
By means of this connection the valve for feeding pneumatic tools gets activated.
Pneumatic connections see chapter 7.1 Connect Compressed air on page 27.
3.1.3. FOOT PEDAL
The crimping process can be started with the foot pedal.
3.1.4. Fuse Holder
The fuse holder contains both main fuses.
3.1.5. Power Supply
One-Phase wi t h pr ot ective earth (2P+E)
100/115 VAC, Fuse T10A
230/240 VAC, Fuse T6A
50/ 60 Hz, 255 VA
Page: 10 of 31
CP-871 REFERENCE MANUAL
4. OPERATING ELEMENTS
4.1. Main Switch
The CP-871 has no main switch. The power supply is cut off by removing the power cord
from the machine or by using the emergency stop button.
Picture 4.1: Main Switch
4.2. Control Panel
Emergency Stop Button
1234567891234567
1234567891234567
Picture 4.2: Control Panel with Keyboard
Page: 11 of 31
Display
Keyboard
LED Operational
4.2.1. Display
1234567891234567
CP-871 REFERENCE MANUAL
1234567891234567
Picture 4.2.1: Display
4.2.2. Keyboard
Escape Key:
Leave the entry mask or the menus
Enter Key:
Activate the entry mask or confirm the
entry
Minus Key:
Minimize the value in a input field or
scroll in the selection menu or in the
sub-menus.
Plus Key:
Increase value in the input field or or
scroll in the selection menu or in the
sub-menus.
Creeping Speed Key – Left:
Moves the machine with reduced speed
against the machining direction
Creeping Speed Key – Right:
Moves the machine with reduced speed
in the machin ing direction
Operational LED:
The LED indicates that th e machine is
in the upper dead center and ready for
use.
Escape Key in the main menu:
By activating the Escape key in the main menu (minimum 1x), the machine returns to the home
position as soon as the machine hits high resistance (e.g. contact material) the rotational
direction changes.
Page: 12 of 31
CP-871 REFERENCE MANUAL
5. MONITORS, MENUS
When starting the CP-871,
the software version is
briefly indicated.
Start menu
Main Menu
Selection menus
Menu Counters Menu Functions Menu Settings
Reset Counter
990900
Set Batch
000900
Total Counter
99090000
Panel V. XX.XX
Drive V. XX.XX
Counter: 999999
Batch: 009999
Menu:
Counters
Menu:
Functions
Menu:
Settings
Crimp Speed
100%
Crimp Force
ON/OFF
Pneumatic Valve
ON/OFF 220ms
Split Cycle
ON/OFF 120°
Split Cycle
Speed 75%
Password
####
Language
English
Contrast:
Setting
Endurance Test
000900
Page: 13 of 31
CP-871 REFERENCE MANUAL
5.1. Main Menu
Counter: 999999
Batch: 009999
SAFETY
COVER OPEN
Counter: 999999
Batch Processed
5.2. Settings
5.2.1. Menu language
Counter: 999999
Batch: 009999
Menu:
Counters
• Lot Counter
• Piec e Counter
• Error Message Display
• Safety cover open, c rimping error, machine not at
home position, activating device not ready.
• Information Display
• Lot processed
• Main Menu
•
, Selection menu „Counters“
Menu:
Settings
Password
####
Password
0###
Language
English
Counter: 999999
Batch: 009999
• With 2 x
• With
•
• Chang e the numerical value
• Repeat the procedure until all four figures have
•
•
•
• 2 x
, Password entry is activated (the first figure
flashes) Password 0200.
the wanted valu e is reached, confirm
second figure flashes).
been entered
, Sub-Menu language setting (if the password
was incorrectly entered the sub-menu cannot be
accessed.
, Function Language setting gets activated.
With
English, French, Italian, Spanish)
, Confirm language.
change to „Settings“ in the menu
log into the sub-menu password
or . Once
. (the
or choose the language (German,
, back to main menu.
Page: 14 of 31
CP-871 REFERENCE MANUAL
5.2.2. Contrast Setting
Counter: 999999
Batch: 009999
• Main Menu
Menu:
Counters
Menu:
Settings
Password
####
Password
0###
Contrast
Setting
•
• With 2 x
• With
•
• Chang e the numerical value
• Repeat the procedure until all four figures have
• 2 x
•
, Selection menu „Counters“
change to „Settings“ in the menu
log into the sub-menu password
, Password entry is activated (the first figure
flashes) Password 0200.
or . Once
the wanted valu e is reached, confirm
second figure flashes).
been entered
,Sub-Menu “contrast setting” (if the
password was incorrectly entered the sub-menu
cannot be accessed.
, Function contrast setting gets activated.
. (the
Set with
•
•
, Confirm settin gs.
or the contrast
Counter: 999999
Batch: 009999
• 2 x
, back to main menu.
Page: 15 of 31
CP-871 REFERENCE MANUAL
5.2.3. Endurance Test
Counter: 999999
Batch: 009999
• Main Menu
Menu:
Counters
Menu:
Settings
Password
####
Password
0###
Endurance Test
000900
•
• With 2 x
• With
•
• Chang e the numerical value
• Repeat the procedure until all four figures have
• 3 x
•
, Selection menu „Counters“
change to „Settings“ in the menu
log into the sub-menu password
, Password entry is activated (the first figure
flashes) Password 0200.
or . Once
the wanted valu e is reached, confirm
second figure flashes).
been entered
, sub-menu „Endurance Test“ (if password
was entered incorrectly, the menu cannot be
selected).
, Function “Endurance Test” is activated. With
or the number of cycles get chosen.
. (the
•
• B y pr es sing
, Confirm entry. the Endurance Test is
activated and the number of cycles chosen are
processed.
. Endurance Test can be
discontinued
Counter: 999999
Batch: 009999
• 2 x
, back to main menu.
Page: 16 of 31
CP-871 REFERENCE MANUAL
5.3. Menu Counters
Counter: 999999
Batch: 009999
Menu:
Counters
Reset Counter
990900
5.3.1. Reset Counter
Reset Counter
990900
Reset Counter
000000
Counter: 999999
Batch: 009999
• Main menu
•
•
•
•
• 2 x
, Selection menu „Cou nters“
With
submenu “Set Batch” with
change to menu „Cou nters“.
, Activate „Reset Counter” (figures flash).
, Reset Counter
, back to the main menu or directly to the
.
5.3.2. Programming Batch
Set Batch
000900
Set Batch
002500
Counter: 999999
Batch: 009999
Counter: 999999
Batch Processed
•
•
• With
•
• 2 x
• Once the Batch is reached „Batch Processed“ will
, Submenu „Set Batch“.
, Activate function „Set Batch“.
or Enter Batch.
, Confirm entry.
, back to main menu or directly to sub-
menu „Total Counter“ with
appear. By pressing
activated. To deactivate the Batch function,
programm a Batch value of „000000“.
the new Batch is
Page: 17 of 31
CP-871 REFERENCE MANUAL
5.3.2.1. Total Counter
Total Counter
99090000
• 2 x
, sub-menu „Total Counter” (Information)
Counter: 999999
Batch: 009999
5.4. Functions
Counter: 999999
Batch: 009999
Menu:
Counters
Menu:
Functions
Crimp Speed
100%
5.4.1. Crimp Speed
• 2 x
menu „Det Batch” or with 2x
„Reset Counter”.
• Main Menu
•
• With
• With
, back to main menu. With into sub-
, Selection menu „Cou nters“
go to menu „Functions“
go to sub-men u „Functions“.
into sub-menu
Crimp Speed
100%
Crimp Speed
080%
Counter: 999999
Batch: 009999
5.4.2. Crimp Force
This feature does not function with PANDUIT product and is not supported by PANDUIT.
•
• With
• 100% Ömax. speed Ö ca. 350ms
• 5% Ömin .speed Ö ca. 1s
•
• 2 x
, „Crimp Speed“ function is activated (figures
are flashing).
and one can adjust the pr es s i n g
speed in percentage.
, accept entry.
, back to main menu or with direct
into the sub-menu „Crimp Force“ (Crimp Force
monitoring).
Page: 18 of 31
CP-871 REFERENCE MANUAL
5.4.3. Pneumatic Valve (Option)
Pneumatic Valve
OFF
Pneumatic Valve
ON 220ms
Counter: 999999
Batch: 009999
A badly set feeder timing may damage the machine. Always install
pneumatic tools without contact material, until the feeder timing is properly
set.
• 2 x
• With
(figures are flashing).
• With
Valve“ function and by p ress the
of the valve can be programmed.
•
The length of time the valve is engaged is
•
permanently programmed and can not be
changed..
• 2 x
directly into the sub-menu „Split Cycle“.
, sub-menu „Pneumatic Valve“.
, „Pneumatic Valve“ function is activated
and activation of the „Pneumatic
, accept entry.
, back to the main menu or with go
key timing
• Connect the compressed air on the pressure
gauge.
• Assemble the tool according to Chapter 6.3
Applicator Assembly on page 23.
• Connec t the applicator to the normally open port
of the pneumatic valve.
• Switch on the air pressure unit using the main
switch at the pressure gauge.
• Set gage at 6 bar processi ng pressure
Page: 19 of 31
5.4.4. Split Cycle
Split Cycle
OFF
Split Cycle
ON 120°
CP-871 REFERENCE MANUAL
• 3 x
•
flashing).
• With
be activated and by press the
breakpoint can be programmed.
, sub-menu „Split Cycle“.
, „Split Cycle“ function is activated (figures are
and the „Split Cycle“ function can
key the
Upper dead
center
Break
point
Split Cycle
Speed 75%
Split Cycle
Speed 45%
Counter: 999999
Batch: 009999
• The „Split Cyc le“ is used mainly for end sleeve
contacts, to centre the contact in the crimping
stamp and to ensure easier handling for the
operator.
• Chang e to the sub-menu „Split Cycle Speed“ with
.
•
• With
• 100% Ö max. Speed.
• 5% Ö min. Speed.
•
• 2 x
• Press the
, „Split Cycle Speed“ function is activated
(figures are flashing).
and the pressing speed can be
adjusted in percent.The speed is programmed
from the upper dead center to the breakpoint.
, accept entry.
, back to the main menu or with back
into the previous menu.
key to initialise the machine (min.
3s)
Page: 20 of 31
CP-871 REFERENCE MANUAL
6. TOOL REPLACEMENT
6.1. Roller Carrier
• Loosen both inner hexagon bolts of the pipe
clamp on the left side of the machine.
side
banded
• Turn the roller carrier 90° to the right for side
banded contacts.
• Set the height according to the contact roll.
• Tighten both hexagon bolts on the pipe clamp.
• Attach the rear dead stop.
• Assemble the contact roll.
• Set the braking power for the contact roll using
the forward dead stop and the spring.
Page: 21 of 31
CP-871 REFERENCE MANUAL
6.2. Contact guide plate
• Loosen both of the knurled screws and lift the
sheet plate.
• Pull the sheet plate to the right and then remove
it.
sidebanded
• Assemble the sheet plate onto the distance bolt at
the left for side feed ap plicators.
Attach the sheet plate using the knurled screws.
•
• The contact material must be fed through the
black leading bracket
• Feed material into the applicator.
Page: 22 of 31
CP-871 REFERENCE MANUAL
6.3. Applicator Assembly
• Open the front guard and remove the contact
material.
• Move the clamping lever on the left downwards
until the clam ps are open.
• Assemble / disassemble the tool in the nut and
after remove at the bottom from the retaining
clamps of the applicato r ground plate.
• Move the clamping lever upwards until the
clamping fingers clamp the tool in their respective
grooves.
• Check that the tool is properly fastened and close
the protective cover.
• Set the tool according to the operating guidelines
set out by the manufacturer.
Page: 23 of 31
CP-871 REFERENCE MANUAL
6.4. Remove lateral cover
To use large tools on the machine a part of the lateral safety cover can be removed.
As part of the tools may protrude laterally from the machine’s guard, these may
come in touch with movable mechanical parts.
If this happens, the machine may no longer conform to the CE standard rules.
Therefore removal of the lateral part of the guard is at ones own risk.
• Open the front guard (safety cover) and remove
contact material
• Loosen both knurled screws and lift the sheet
plate.
• Pull the sheet plate to the right and remove.
• Loosen both inside hexagonal screws.
• Remove the lateral cover piece.
• Assemble the tool and the contact lead.
To ensure safety, assemble the lateral cover piece removed immediately after
use.
Page: 24 of 31
CP-871 REFERENCE MANUAL
6.5. Setting the Crimp Height
The crimping height of the CA-800EZ and CA9 applicators can be adjusted within the
applicator. Further crimp height adjustments can be made to the press itself.
After each tool change, (before the first crimp), set the height of the machine to 0
Not doing so may damage the tool.
Only qualified personnel may carry out this setting.
• Micro adj ustment of the crimp height.
• Turn the flange toothed surface.
• Minus direction, towards the left, increases the
crimping height. (e.g. 1.27 => 1.30).
• Plus direction, towards the right, decreases the
crimping height (e.g. 1.27 => 1.24).
• The setting is limited to ± 0.25 mm.
• The graduation is 0.025 mm per line.
The reference point (135.788 mm) is marked with
•
the figure 0.
• Should the height setting not be used, this
function can be blocked by tightening the inner
hexagonal screw.
Page: 25 of 31
CP-871 REFERENCE MANUAL
7. START-UP
The CP-871 may only be started-up by trained personnel (Panduit personnel or
trained personnel at the user).
• After unpacking use the included lifting column and lift the machine with a crane or
another auxiliary device onto a leveled working area (table, workbench, etc.)
• Open the safety cover and remove any packaging residuals.
• Connect the foot pedal.
• Plug in the line cord.
Page: 26 of 31
CP-871 REFERENCE MANUAL
7.1. Connect Compressed air
• The air pressure’s entry pressure may never exceed 7 bar / 0.7 MPa
• Operating pressure must be set at a minimum of 4-5 bar / 0.4-0.5 MPa
• Use only dry, clean, oil free air pressure.
Connect the compressed air to the service unit.
•
• Adjust the operating pressure.
To do so pull the setting button from the interlock and turn clockwise until the
manometer shows 4-5 bar (0.4-0.5 MPa). Press the setting button downward until it
engages.
Picture 7.1: Connect Compressed air
Setting Button
Manometer
Main switch
Connection
Page: 27 of 31
CP-871 REFERENCE MANUAL
8. PRODUCTION
• Engage the CP-871 by plugging the line cord and/or unlocking the Emergency-Off
button. The CP-871 activates itself.
• Set the menu language according to the instructions in chapter 5.2.1 Menu
language on page 14.
• Assemble the contact material according to the instructions in chapter 6.1 Roller
Carrier on page 21 and chapter 6.2 Contact guide plate on page 22.
• Assemble the applicator according to the applicator instructions in chapter 6.3
Applicator Assembly on page 23.
8.1. Production start
• Lead the cable through the opening of the protection cover to the applicator’s wire
stop or using the plug connection as a reference.
Picture 8.1: Production start
• The cycle will be activated only when the green LED is on.
• Processing is activated with the foot pedal.
• The crimping press moves the tool into the bottom dead center and after that to
the upper dead center.
• The tool separates the plug connection from the belting band, crimps the plug
connector onto the conductor and feeds a new plug connector into position. The
belting band gets cut by the tool.
• Remove the cable with the crimped connector.
• As soon as the LED on the control panel turns green the next cycle can be
activated.
Page: 28 of 31
CP-871 REFERENCE MANUAL
9. FAULT MESSAGES
Fault Diagnosis Action
Message:
Protection Cover open
Message:
Machine not in home
Position
Message:
Crimp Drive not ready
Message:
CFM not ready
No display on the monitor
• Protection cover open
• Machine is not in the upper
dead center or blocked
• 15 V Error
Over current fault
•
• Over temperature fault
• Watchdog fault
Crimp force monitoring
•
without function.
• Power supply not connected
• Fuse defect
• Emergency stop activated
• Connect protection cover to
CP-871.
• With the help of
return to Home Position. The
green LED glows
• By activating the
the main menu (minimum 3x),
the machine returns to the
home position. The machine
changes the turning direction
automatically as soon as it is
in contact with a resistor.
• Check fuse on print
machine over-loaded
•
• replace drive
Turn on CFM and check the
•
connection of the cable.
• Set the CFM to the
production menu.
• Disengage the emergency-off
button or plug in power.
• Check the fuse
or
key in
Machine does not switch
on
Wrong crimping height
Contact material does not
feed correctly
• Power supply not connected
• Fuse defect
• Emergency stop activated
• Crimp height not adjusted • Adjust the crimp height on the
• Roller carrier wrong adjusted
• Contact break wrong
adjusted
• Contact guide plate wrong
mounted
Page: 29 of 31
• Disengage the emergency-off
button
• Plug in power
Check fuse on the power
•
supply.
machine adjustment.
• Adjust the position of the roll
on the roller carrier.
• Set the contact break.
• Mount the contact guide right.
The contact material must be
fed trough the black leading
bracket.
CP-871 REFERENCE MANUAL
10. DISPOSAL
The equipment must be properly disposed of according to the local and legal regulations.
10.1. Packaging
The packaging consists of environment friendly materials such as wood, nails, cardboard,
paper and synthetics and can be disposed of as regular waste.
10.2. Machine
The machine is made up of 90% aluminium and steel, 5% other metals and up to 5%
electric materials and synthetics.
The environmentally friendly disposal of the machine must be done according to each
country legal regulations.
Page: 30 of 31
CP-871 REFERENCE MANUAL
Index
A
Application................ .............................................7
Application Limits...................................................7
Applicator Assembly............................................23
C
CFM not ready .................................................29
CIRCUIT POINTS................................................10
Connect Compressed air.....................................27
Connector... ....................................................... ....9
Contact guide plate..............................................22
Contact material does not feed correctly..29
Contrast Setting...................................................15
Control Panel.......................................................11
Crimp Drive not ready............................. .......29
Crimp Force.........................................................18
Crimp Speed............................... .........................18
Crimping Connections ......................... ..... .... ..... ....9
D
Danger Areas ........... ......... ..... .... ..... ......... .... ..... ....8
Display.................................................................12
Disposal...............................................................30
E
Endurance Test........................................ ...........16
F
Fault Messages...................................................29
Functions.............................................................18
Fuse Holder....................................................... ..10
K
Keyboard.............................................................12
M
Machine...............................................................30
Machine does not switch on ........................29
Machine not in home Position.....................29
Main Menu.......................................................... 14
Main Switch ........................................................ 11
Menu Counters................................................... 17
Menu language........... ........................................ 14
Monitors, Menus................................................. 13
N
No display on the monitor ......... .................. 29
P
Packaging........................................................... 30
Pneumatic Valve................................................. 19
Power Supply...................................................... 10
Processing............................................................ 9
Production........................................................... 28
Programming Batch............................................ 17
Protection Cover open
R
Remove lateral cover.......................................... 24
Reset Counter...................... ............................... 17
Roller Carrier ................................ ...................... 21
S
Security Tag........................................... ......... ..... . 6
Security Tags ..... .... ..... .... ......... ..... .... ..... ......... ..... . 6
Setting the Crimp Height..................................... 25
Settings............................................................... 14
software-Version................................................. 13
Split Cycle......... .................................................. 20
START-up........................................................... 26
T
Tag .......... ............................................................. 7
Technical Data...................................................... 8
Total Counter...................................................... 18
W
.................................. 29
Wrong crimping height................................. 29
Page: 31 of 31
© Panduit Corp. 2006
CP-871
SPARE PARTS MANUAL
PA25085A01
Rev. 00 3-2006
Website: www.panduit.com
E-mail: cs@panduit.com
Technical Support:
888-506-5400, ext. 3255
Fax: (630) 759-7532
CP-871 SPARE PARTS MANUAL
Part Number Name
CA32147A01 Pneumatic feed
CA32148A01 Lamp 230 VAC
CA32149A01
TP25130B01
TP25131B01
CA32152A01
Lamp 115 VAC
Finger protection
Hole Cover
Power Cord Europe
Page: 1 of 2
CP-871 SPARE PARTS MANUAL
Part Number Name
CA32153A01
CA32154A01
CA32155A01
CA32156A01
Power Cord USA
Fuses 6.3 A/T 5x20 (230V)
Fuses 10A/T SPT 5x20 (115V)
Foot pedal
CA32157A01
CA32158A01
CA32159A01
Grease Microlube GBUY 131
Hex Key Set
Packaging
Page: 2 of 2
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