The use of products described in this manual is oriented exclusively to qualified electricians
or persons instructed by them, who are familiar with applicable standards and other regulations regarding electrical engineering and, in particular, the relevant safety concepts.
Explanation of symbols used and signal words
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety measures that follow this symbol to avoid possible injury or death.
There are three different categories of personal injury that are indicated with a
signal word.
DANGERThis indicates a hazardous situation which, if not avoided, will re-
sult in death or serious injury.
WARNING This indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTIONThis indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
This symbol together with the signal word NOTE and the accompanying text
alert the reader to a situation which may cause damage or malfunction to the
device, hardware/software, or surrounding property.
This symbol and the accompanying text provide the reader with additional information or refer to detailed sources of information.
How to contact us
InternetUp-to-date information on Phoenix Contact products and our Terms and Conditions can be
found on the Internet at:
www.phoenixcontact.com
Make sure you always use the latest documentation.
It can be downloaded at:
www.phoenixcontact.net/catalog
SubsidiariesIf there are any problems that cannot be solved using the documentation, please contact
your Phoenix Contact subsidiary.
Subsidiary contact information is available at www.phoenixcontact.com
Published byPHOENIX CONTACT GmbH & Co. KG
Flachsmarktstraße 8
32825 Blomberg
GERMANY
Should you have any suggestions or recommendations for improvement of the contents and
layout of our manuals, please send your comments to:
tecdoc@phoenixcontact.com
.
4
PHOENIX CONTACT102576_en_04
Page 5
Please observe the following notes
General terms and conditions of use for technical documentation
Phoenix Contact reserves the right to alter, correct, and/or improve the technical documentation and the products described in the technical documentation at its own discretion and
without giving prior notice, insofar as this is reasonable for the user. The same applies to any
technical changes that serve the purpose of technical progress.
The receipt of technical documentation (in particular user documentation) does not constitute any further duty on the part of Phoenix Contact to furnish information on modifications
to products and/or technical documentation. You are responsible to verify the suitability and
intended use of the products in your specific application, in particular with regard to observing the applicable standards and regulations. All information made available in the technical
data is supplied without any accompanying guarantee, whether expressly mentioned, implied or tacitly assumed.
In general, the provisions of the current standard Terms and Conditions of Phoenix Contact
apply exclusively, in particular as concerns any warranty liability.
This manual, including all illustrations contained herein, is copyright protected. Any
changes to the contents or the publication of extracts of this document is prohibited.
Phoenix Contact reserves the right to register its own intellectual property rights for the
product identifications of Phoenix Contact products that are used here. Registration of such
intellectual property rights by third parties is prohibited.
Other product identifications may be afforded legal protection, even where they may not be
indicated as such.
English
102576_en_04PHOENIX CONTACT5
Page 6
CF 500...
Table of contents
1Basic information .......................................................................................................................7
A 1Ordering data ...................................................................................................... 19
A 2Technical data.....................................................................................................21
6
PHOENIX CONTACT102576_en_04
Page 7
1Basic information
For safe handling and trouble-free operation of the CF 500, you must be familiar with and
observe the safety notes.
1.1Intended use
WARNING: The CF 500 is intended solely for crimping.
Only crimping dies with suitable cross sections may be used (see "Crimping dies and protective covers" on page 19).
Under no circumstances should solid metal parts or other similar objects be inserted.
This damages the crimping die.
Unauthorized conversions that exceed the scope of modification, and changes to the
CF 500 are not permitted for safety reasons.
NOTE: Correct usage includes observing all notes and complying with the predefined
operating conditions.
WARNING: The CF 500 may only be used
–as intended and
–in a safe, and fault-free condition.
Basic information
English
WARNING: All persons responsible for startup, operation, and maintenance of the
CF 500 must be appropriately qualified and adhere strictly to this user manual.
The CF 500 is used for crimping various types of crimp contacts:
–Ferrules
–TWIN ferrules
–Turned contacts
–Slip-on sleeves and flat plugs
–Insulated cable lugs
–Cable lugs
–Tube lugs
Other crimp contacts on request.
Permitted operators
Only authorized and instructed operators may work with the CF 500.
The operator is responsible for all other persons within the workspace.
The owner must make the user manual available to the operator and ensure that the operator has read and understood it.
WARNING: Only use original crimp dies and replacement parts from Phoenix Contact.
102576_en_04PHOENIX CONTACT7
Page 8
CF 500...
1.2Workplaces
NOTE: During operation and storage, avoid the following:
–Humid or dusty places and
–Locations exposed to high levels of heat, direct sunlight or low temperatures (operat-
ing range: 10°C to 40°C).
NOTE: Do not spill liquids on the CF 500.
Do not expose the CF 500 to strong vibrations or shocks.
1.3For your safety
WARNING: The protective cover is fitted for the safety of the operator. Under no circum-
stances must it be modified, removed or bypassed by means of alterations.
WARNING: The CF 500 must only be operated with the protective cover attached.
Disconnect the mains plug prior to all work that requires removal of the protective cover
(e.g., crimping die adjustment).
Switch off the electric crimper during breaks and when the device is not being used.
For reasons of safety, the CF 500 automatically switches off when the protective cover is removed.
WARNING: Disconnect the mains plug before opening the housing.
1 Control panelSelection of operating functions and display of device states.
2 CounterThe counter records each complete crimping process. The counter reading is saved for ap-
proximately one week when the device is switched off.
3 Adjusting slideThe adjusting slide sets the area in which the crimping die is compressed with full force. If the
die meets with resistance outside this area, the crimping pliers are opened immediately.
(1 = minimum area, 5 = maximum area.)
4 Crimping diePositions the crimp contact and crimps this with the wire.
5 Protective coverThe protective cover prevents injury in the crimping die danger zone. The CF 500 can only be
operated when the protective cover is fully attached.
6 Carrier handleThe carrier handle is used for transporting the CF 500.
7 Foot pedal connectionDevice connection for the foot pedal.
8 Mains connectionDevice connection for the power cable.
9 Mains fusesMicro fuses integrated into the mains connection (2x).
10 Mains switchThe mains switch switches the power supply on (I pressed) or off (0 pressed). The "ready"
LED lights up when switched on.
11 Foot pedalThe foot pedal initiates the crimping process.
102576_en_04PHOENIX CONTACT9
Page 10
CF 500...
2.3 Function of the operating components
"Ready" LED – indicates that the unit is
ready for operation.
"Reset" button – resets the counter reading to zero.
"Operating mode 1" – switches the
CF 500 to operating mode 1 (LED lights up).
In operating mode 1, the crimping process
takes place in one step.
"Operating mode 2" button – switches
the CF 500 to operating mode 2 (LED lights
up). In operating mode 2, the crimping process takes place in two steps. In the first
step, only the contact is fixed in the die.
2.4Scope of use of the CF 500
"Error" LED – indicates that crimping failed or
that there is a malfunction.
Press the "enter" button, the LED goes out and
you can continue to crimp.
"Service" LED – indicates that the CF 500 requires servicing. We recommend servicing by
Phoenix Contact after 500,000 crimping processes in order to ensure a consistent level of
crimping quality.
"Enter" button – clears the "Error" LED.
Buttons for limiting the opening – the opening
of the crimping die can be adjusted by pressing
the upper (open) or lower (close) button. The
LEDs indicate the opening status:
Changes are only effective once the next crimping procedure has been carried out.
The CF 500 electric crimper is used for crimping crimp contacts.
By using different crimping dies, various types of crimp contacts with a wide range of cross
sections can be processed.
The CF 500 can be operated in two different operating modes:
–Operating mode 1: The crimp contact is crimped when the foot pedal is pressed.
–Operating mode 2: The foot pedal is pressed twice. The first press secures the insert-
ed contact in the die. The second time the foot pedal is pressed, the crimp contact is
crimped.
The press capacity can be adjusted. This prevents damage to the tools and faulty crimping
due to incorrectly inserted contacts.
The opening stroke of the crimping die can be changed by simply pressing a button.
For precise crimping, a moveable locator, which positions the contacts directly under the
crimping stamp, can be fitted.
Available crimping diesAvailable crimping dies are listed in the "Crimping dies and protective covers" ordering data
on page 19. A protective cover with a suitable insertion slot is assigned to each crimping die.
10
PHOENIX CONTACT102576_en_04
Page 11
3Starting up the CF 500
NOTE: The device must be set up on a level
and horizontal surface.
NOTE: During operation and storage, avoid
the following:
–Humid or dusty places and
–Locations exposed to high levels of heat,
direct sunlight or low temperatures (operating range: 10°C ... 40°C).
WARNING: Risk of injury
Disconnect the mains plug before removing the
protective cover.
3.1Overview
To start up the electric crimper, you must carry out the following steps:
–Set up the CF 500
–Remove the protective cover
–Fit the crimping die
–Attach the protective cover
–Connect and switch on the CF 500
–Center the crimping die
–Adjust the crimping die
–Prepare the unit for operation
–Set the optimum press capacity start
–Set the optimum opening stroke
3.2How to proceed
Setting up the CF 500
Starting up the CF 500
English
Removing the protective cover
•Unscrew the screw (1).
•Remove the protective cover (2).
102576_en_04PHOENIX CONTACT11
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CF 500...
NOTE: Observe the mounting position:
–Small cross section to the front
–Large cross section to the rear
WARNING: The CF 500 must only be operated
with the protective cover attached.
NOTE: If the protective cover is missing or incorrectly attached, then the CF 500 power supply disconnects.
NOTE: The CF 500 is available in two versions
for 230 V and 120 V. Make sure the mains connection is correct (see rating plate).
Fitting the crimping die
•Insert the lower crimping die (1).
•Gently tighten the screw (2).
•Insert the upper crimping die (3).
•Gently tighten the screw (4).
Attaching the protective cover
•Insert the security pin (1) into the lower crimping die and
slide the protective cover (2) in until you feel it engage.
12
PHOENIX CONTACT102576_en_04
Connecting and switching on the CF 500
•Connect the foot pedal (1) to the foot pedal connection.
•Connect the mains plug (2) to the mains connection and
the shock-proof plug (3) to the socket.
•Switch on the CF 500 with the mains switch (4) (press I).
The "ready" LED lights up (5).
Page 13
Starting up the CF 500
NOTE: The crimping die bore holes have some
play for the mounting screws. Therefore you
need to center and adjust the crimping die.
NOTE: Only release the foot pedal once the
crimping die is closed. Otherwise it opens automatically, adjustment mode is terminated, and
the "error" LED lights up.
WARNING: Risk of injury
Disconnect the mains plug before removing the
protective cover.
Centering the crimping die
•Press the "operating mode 2" and "enter" buttons simul-
taneously (1).
•The LEDs for the "operating mode 1 + 2" buttons flash
(2).
•Push the adjusting slide (3) to position 1.
•Press and hold down the foot pedal (4).
•The crimping die (5) closes slowly, until it meets with re-
sistance and centers itself.
•Release the foot pedal (6).
English
Adjusting the crimping die
•Switch off the CF 500 with the mains switch (1)
(press 0).
•Disconnect the mains plug (2).
•Unscrew the screw (7).
•Remove the protective cover (3).
•Check the centering of the crimping die, adjust if neces-
sary (4).
•Tighten the screws (5).
•Attach the protective cover (6) and tighten the screw
(7).
102576_en_04PHOENIX CONTACT13
Page 14
CF 500...
NOTE: The device is set to operating mode 2.
Check the operating mode before each use.
1
NOTE: Ensure the cross section is correct.
NOTE: Changes to settings only take effect af-
ter the next crimping process.
Preparing the unit for operation
•Plug in the mains plug (1).
•Switch on the mains switch (2) (press I).
The "ready" LED lights up (3).
•Press the foot pedal (4).
•The crimping die (5) opens automatically; release the
foot pedal (6).
The "error" LED lights up (7).
•Press the "enter" button (8).
The CF 500 is ready to operate.
Setting the optimum press capacity start (1 ... 5)
•Push the adjusting slide (1) into position 1.
•Use the button to set "operating mode 1".
•Press the foot pedal.
One crimp process is performed without an inserted
crimp contact. If the "error" LED lights up, check the position of the crimping die (see page 13).
•Insert the wire and the crimp contact.
•Press the foot pedal.
•If the "error" LED lights up, move the adjusting slide up
one position.
•Press the "enter" button.
•Repeat the process until the "error" LED no longer lights
up.
•To compensate for any material tolerances, push the
adjusting slide up one more position.
Setting the optimum opening stroke
•Press the upper button until all four LEDs light up.
The maximum opening stroke is set.
•Carry out the crimping process.
•If the opening stroke is too large, press the lower button
so that only three LEDs light up.
•Carry out the crimping process.
•Repeat the process until the optimum opening stroke is
set.
14
PHOENIX CONTACT102576_en_04
Page 15
4Operation
NOTE: Ensure the cross section is correct.
NOTE: If there was a fault with the crimping, the
"error" LED lights up (see page 17).
4.1One-step crimping
Setting operating mode 1
•Switch on the CF 500 with the mains switch (1)
(press I).
The "ready" LED lights up (2).
•Press the "operating mode 1" button (3).
•If necessary, read the counter (4) and press the
"reset" button to reset it to zero (5).
Crimping the crimp contact
•Center the crimp contact (1) on the lower crimping die.
•Insert the wire (2) into the crimp contact.
Operation
English
•Press the foot pedal (3) until the crimping die is com-
pletely closed (4).
•The crimping die (5) opens automatically; release the
foot pedal (6).
•Remove the crimp contact with crimped wire (7).
Shutting down
•If necessary, read the counter (1).
•Switch off the CF 500 with the mains switch (2)
(press 0).
102576_en_04PHOENIX CONTACT15
Page 16
CF 500...
NOTE: Ensure the cross section is correct.
NOTE: If there was a fault with the crimping, the
"error" LED lights up (see page 17).
4.2Two-step crimping
Setting operating mode 2
•Switch on the CF 500 with the mains switch (1)
(press I).
The "ready" LED lights up (2).
•Press the "operating mode 2" button (3).
•If necessary, read the counter (4) and press the
"reset" button to reset it to zero (5).
Clamping the crimp contact
•Center the crimp contact (1) on the lower crimping die.
•Press the foot pedal (2) until the crimp contact is
clamped (3).
•Release the foot pedal (4).
Crimping the crimp contact
•Insert the wire (1) into the crimp contact.
•Press the foot pedal (2) until the crimping die is com-
pletely closed (3).
•The crimping die (4) opens automatically; release the
foot pedal (5).
•Remove the crimp contact with crimped wire (6).
Shutting down
•If necessary, read the counter (1).
•Switch off the CF 500 with the mains switch (2)
(press 0).
16
PHOENIX CONTACT102576_en_04
Page 17
5Troubleshooting
WARNING: Risk of injury
Disconnect the mains plug before removing the
protective cover.
5.1"Error" LED lights up
Troubleshooting
This malfunction can be caused by:
–Foot pedal released too soon
–Incorrect cross section selected
–Incorrectly set press capacity start (1 ... 5)
–Crimping die incorrectly adjusted
Foot pedal released too soon
If the foot pedal is released too soon, the crimping die immediately opens up as far as its initial position.
•Press the "enter" button.
The "error" LED goes out.
•Repeat the crimping process.
Incorrect cross section selected
If a crimp contact that is too large or another unsuitable object is inserted, the crimping process is interrupted due to
overload and the crimping die immediately opens as far as
its initial position.
•Press the "enter" button.
The "error" LED goes out.
•Repeat the crimping process with the correct cross section.
Incorrectly set press capacity start (1 ... 5)
The inserted contact is too large for the selected area.
•Push the adjusting slide up one position.
•Press the "enter" button.
The "error" LED goes out.
•Repeat the crimping process until the press capacity is
optimally set.
English
Crimping die incorrectly adjusted
•Switch off the CF 500 with the mains switch (1)
(press 0).
•Disconnect the mains plug (2).
•Unscrew the screw (3).
•Remove the protective cover (4).
•Loosen the screws (5).
•Carry out the startup steps (see Section 3).
102576_en_04PHOENIX CONTACT17
Page 18
CF 500...
WARNING: Risk of injury
Switch off the CF 500 via the mains switch and
disconnect the mains plug.
NOTE: The fuse holder must snap into place.
5.2CF 500 will not switch on
The CF 500 will not switch on. The "ready" LED does not
light up. This malfunction can be caused by:
–No mains connection
–Mains fuse blown
No mains connection
•Check whether the mains plug is connected to the
CF 500 mains connection and the shock-proof plug is
connected to the mains socket.
•Make sure that the power supply at the mains socket is
OK.
Mains fuse blown
•Switch off the CF 500 with the mains switch (1)
(press 0).
•Disconnect the mains plug (2).
•Pull out the fuse holder (3).
•Check the mains fuses (4).
•Replace the blown mains fuse (for Order No. see order-
ing data on page 19).
•Insert the fuse holder..
18
PHOENIX CONTACT102576_en_04
Page 19
A Appendix
A 1Ordering data
Electric crimper
DescriptionTy p eOrder No.
Electric crimper 230 VCF 500-230V1208348
Electric crimper 120 VCF 500-120V1208351
Mains fuse for CF 500-230VFUSE SB 1.25 A1208801
Mains fuse for CF 500-120VFUSE SB 2.5 A1209062
Crimping dies and protective covers
CF 500/DIE AI 6CF 500/COV AI 6CF 500/DIE AI 25CF 500/COV
Order No. 1212238Order No. 1212254Order No. 1212239Order No. 1212250
1
English
For ferrules (A… and AI…), 0.25 ... 6 mm
CF 500/DIE AI 50CF 500/COV
2
1
For ferrules (A… and AI…), 10, 16, and 25 mm²
CF 500/DIE AI-TWIN 10CF 500/COV AI-TWIN
Order No. 1212261Order No. 1212250Order No. 1212262Order No. 1212266
For ferrules (A… and AI…), 35 and 50 mm²
CF 500/DIE TC 4CF 500/COV
1
CF 500/DIE TC 10CF 500/COV
For TWIN ferrules (AI-TWIN), 2 x 4, 2 x 6, and 2 x 10 mm²
1
Order No. 1212237Order No. 1212250Order No. 1212260Order No. 1212250
Order No. 12122462)Order No. 1212252Order No. 12122562)Order No. 1212250
For tube lugs according to DIN 46235, 4 ... 10 mm²For tube lugs (special), 4 ... 10 mm²
1)
2)
20
CF 500 - Protective cover without recess
∅ e/i (external/internal diameter, in millimeters), in relation to the cross section of the cable lug
PHOENIX CONTACT102576_en_04
Page 21
Locator for slip-on sleeves and flat plugs
For precise crimping, a moveable locator, which precisely positions the contacts under the
crimping stamp, can be fitted.
English
Ty p eOrder
No.
CF 500/LOC SCF
1212247 Slip-on sleeves
6,3/6
CF 500/LOC SCF
1212248 Slip-on sleeves
4,8/2,5
CF 500/LOC SCF
1212249 Slip-on sleeves
2,8/1,5
CF 500/LOC SCM
1212264 Flat plug (SCM...),
6,3/2,5
CF 500/LOC SCM
1212265 Flat plug (SCM...),
6,3/6
Crimp contactsDieProtective
cover
CF 500/DIE SC 6CF 500/COV SC
(SCF…) up to 6.3 mm
wide
(SCF…) up to 4.8 mm
CF 500/DIE SC 1,5
CF 500/DIE SC 6
CF 500/COV SC
wide
(SCF…) up to 2.8 mm
CF 500/DIE SC 1,5
CF 500/DIE SC 6
CF 500/COV SC
wide and 5 mm long
0.5 ... 2.5 mm²
1.5 ... 6 mm²
CF 500/DIE SC 1,5
CF 500/DIE SC 6
CF 500/DIE SC 1,5
CF 500/DIE SC 6
CF 500/COV SC
CF 500/COV SC
A 2Technical data
Technical data
Mains connection
CF 500-230V
CF 500-120V
Power consumption160 VA
Maximum press capacity10 kN
Press time< 1 s
Counter6-digit LCD, can be reset
Dimensions (W x H x D)140 mm x 220 mm x 320 mm
Weight of basic device10 kg
Weight of foot pedal1.2 kg
102576_en_04PHOENIX CONTACT21
230 V/50 Hz
120 V/60 Hz
Page 22
CF 500...
22
PHOENIX CONTACT102576_en_04
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