Phoenix Contact CF 500 Operating instructions

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Electric crimper CF 500
User manual
UM EN CF 500
Page 2
Page 3
User manual
Electric crimper CF 500
2016-10-18
Designation:
Revision:
Order No.:
This user manual is valid for:
Designation Order No. CF 500-230V 1208348 CF 500-120V 1208351
UM EN CF 500
04
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CF 500...

Please observe the following notes

User group of this manual

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.
DANGER This 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.
CAUTION This 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

Internet Up-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
Subsidiaries If 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 by PHOENIX 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
.
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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
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CF 500...

Table of contents

1 Basic information .......................................................................................................................7
1.1 Intended use.......................................................................................................... 7
1.2 Workplaces ...........................................................................................................8
1.3 For your safety.......................................................................................................8
2 Description of the CF 500 ..........................................................................................................9
2.1 Supplied as standard.............................................................................................9
2.2 Overview of the operating components .................................................................9
2.3 Function of the operating components................................................................10
2.4 Scope of use of the CF 500 .................................................................................10
3 Starting up the CF 500 .............................................................................................................11
3.1 Overview .............................................................................................................11
3.2 How to proceed ...................................................................................................11
4 Operation .................................................................................................................................15
4.1 One-step crimping...............................................................................................15
4.2 Two-step crimping...............................................................................................16
5 Troubleshooting ....................................................................................................................... 17
5.1 "Error" LED lights up............................................................................................17
5.2 CF 500 will not switch on .....................................................................................18
A Appendix .................................................................................................................................. 19
A 1 Ordering data ...................................................................................................... 19
A 2 Technical data.....................................................................................................21
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1 Basic information

For safe handling and trouble-free operation of the CF 500, you must be familiar with and observe the safety notes.

1.1 Intended 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.
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CF 500...

1.2 Workplaces

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.

1.3 For 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.
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2 Description of the CF 500

2.1 Supplied as standard

2.2 Overview of the operating components

Description of the CF 500
1 Basic device CF 500 2 Protective cover 3 Power cable 4 Foot pedal
User manual
English
1 Control panel Selection of operating functions and display of device states. 2 Counter The counter records each complete crimping process. The counter reading is saved for ap-
proximately one week when the device is switched off.
3 Adjusting slide The 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 die Positions the crimp contact and crimps this with the wire. 5 Protective cover The 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 handle The carrier handle is used for transporting the CF 500. 7 Foot pedal connection Device connection for the foot pedal. 8 Mains connection Device connection for the power cable. 9 Mains fuses Micro fuses integrated into the mains connection (2x). 10 Mains switch The mains switch switches the power supply on (I pressed) or off (0 pressed). The "ready"
LED lights up when switched on.
11 Foot pedal The foot pedal initiates the crimping process.
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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.

2.4 Scope 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:
4 LEDs light up: Maximum opening – No LEDs light up: Minimum opening
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 dies Available 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.
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3 Starting 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.

3.1 Overview

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

3.2 How 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).
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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.
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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).
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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).
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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.
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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).

4.1 One-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).
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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).

4.2 Two-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).
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5 Troubleshooting

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).
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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.

5.2 CF 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..
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A Appendix

A 1 Ordering data

Electric crimper
Description Ty p e Order No.
Electric crimper 230 V CF 500-230V 1208348 Electric crimper 120 V CF 500-120V 1208351 Mains fuse for CF 500-230V FUSE SB 1.25 A 1208801 Mains fuse for CF 500-120V FUSE SB 2.5 A 1209062
Crimping dies and protective covers
CF 500/DIE AI 6 CF 500/COV AI 6 CF 500/DIE AI 25 CF 500/COV
Order No. 1212238 Order No. 1212254 Order No. 1212239 Order No. 1212250
1
English
For ferrules (A… and AI…), 0.25 ... 6 mm
CF 500/DIE AI 50 CF 500/COV
2
1
For ferrules (A… and AI…), 10, 16, and 25 mm²
CF 500/DIE AI-TWIN 10 CF 500/COV AI-TWIN
Order No. 1212261 Order No. 1212250 Order No. 1212262 Order No. 1212266
For ferrules (A… and AI…), 35 and 50 mm²
CF 500/DIE TC 4 CF 500/COV
1
CF 500/DIE TC 10 CF 500/COV
For TWIN ferrules (AI-TWIN), 2 x 4, 2 x 6, and 2 x 10 mm²
1
Order No. 1212237 Order No. 1212250 Order No. 1212260 Order No. 1212250
For turned contacts (CK...), 0.14 ... 4 mm² For turned contacts (CK…), 6 ... 10 mm²
CF 500/DIE SC 1,5 CF 500/COV SC CF 500/DIE SC 6 CF 500/COV SC
Order No. 1212241 Order No. 1212251 Order No. 1212242 Order No. 1212251
For slip-on sleeves and flat plugs (SCF..., SCM…),
0.1 ... 1.5 mm²
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For slip-on sleeves and flat plugs (SCF…, SCM…),
0.5 ... 6 mm²
Page 20
CF 500...
e/i
4 mm² 5/3 6 mm² 6.5/3.8 10 mm² 7/4.5
e/i
4 mm² 5/3 6 mm² 5.5/3.8 10 mm² 6/4.5
e/i
4 mm² 5/3 6 mm² 6/4 10 mm² 8/5
CF 500/DIE RCI 6 CF 500/COV RCI CF 500/DIE RCI 1,5 CF 500/COV RCI
Order No. 1212240 Order No. 1212255 Order No. 1212263 Order No. 1212255
For insulated cable lugs (RCI, FCI,...), 0.5 ... 6 mm² For insulated cable lugs (RCI, FCI,...), 0.14 ... 1.0 mm²
CF 500/DIE RCI 6-1 CF 500/COV RCI CF 500/DIE SR 6-2 CF 500/COV RCI
Order No. 1212691 Order No. 1212255 Order No. 1212692 Order No. 1212255
For insulated cable lugs (C-RCI, C-FCI) 0.5 ... 6 mm²,
For solar contacts 2.5 ... 6 mm²
asymmetrical crimp shape, also suitable for insulated slip-on
sleeves with metallic insulation support
CF 500/DIE RC 10 CF 500/COV RC 10 CF 500/DIE RC 16 CF 500/COV
1
Order No. 1212244 Order No. 1212252 Order No. 1212257 Order No. 1212250
For cable lugs according to DIN 46234 (RC, FC,…),
For cable lugs according to DIN 46234, (RC, FC,…), 16 mm²
0.5 ... 10 mm²
CF 500/DIE RCT 2,5 CF 500/COV RCT 2,5 CF 500/DIE RCT 10-1 CF 500/COV RC 10
Order No. 1212243 Order No. 1212253 Order No. 1212245
2)
Order No. 1212252
For tube lugs, 0.34 ... 2.5 mm² For tube lugs (standard), 4 ... 10 mm²
CF 500/DIE RCT 10-2 CF 500/COV RC 10 CF 500/DIE RCT 10-3 CF 500/COV
1
Order No. 12122462) Order No. 1212252 Order No. 12122562) Order No. 1212250
For tube lugs according to DIN 46235, 4 ... 10 mm² For 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 CONTACT 102576_en_04
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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 e Order
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 contacts Die Protective
cover
CF 500/DIE SC 6 CF 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 2 Technical data

Technical data
Mains connection
CF 500-230V CF 500-120V
Power consumption 160 VA Maximum press capacity 10 kN Press time < 1 s Counter 6-digit LCD, can be reset Dimensions (W x H x D) 140 mm x 220 mm x 320 mm Weight of basic device 10 kg Weight of foot pedal 1.2 kg
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230 V/50 Hz 120 V/60 Hz
Page 22
CF 500...
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