Rittal R8 E Operating Instructions Manual
AS 4050.454
Electrical crimping machine R8 E
Operating instructions
Contents
EN
Contents
1 About this documentation .................................................. 4
2 General safety instructions ................................................. 5
2.1 Intended use .......................................................................................... 5
2.2 Not permitted ......................................................................................... 5
2.3 Machine dangers ................................................................................... 5
2.4 Operational hazards ............................................................................... 5
2.5 Hazard sources ...................................................................................... 5
2.6 Safety equipment ................................................................................... 5
2.7 Warning signs at and on the machine or components ............................ 6
2.8 Residual risks ......................................................................................... 6
2.9 Safety measures at the installation site ................................................... 6
2.10 Notes for the operating company ........................................................... 7
2.11 Personnel requirements ......................................................................... 7
2.11.1 Operator ........................................................................................................... 7
2.11.2 Technician ........................................................................................................ 7
2.12 Training and instruction .......................................................................... 7
2.13 Noise ..................................................................................................... 8
3 Device description .............................................................. 8
3.1 Overview ................................................................................................ 8
3.2 Technical data ........................................................................................ 9
4 Transporting the machine ................................................. 10
5 Setting up the machine .................................................... 10
5.1 Operating tools .................................................................................... 10
5.2 Machine connection ............................................................................. 10
5.3 Inserting the belt roll ............................................................................. 11
5.4 Cross-section setting ........................................................................... 12
5.4.1 Die size setting ............................................................................................... 13
5.4.2 Insulation stripping stage setting ..................................................................... 14
5.5 Replacing the belt roll ........................................................................... 14
5.6 Conductor insertion / conductor cutting ............................................... 14
6 Menu ............................................................................... 15
6.1 Jogging operation ................................................................................ 15
6.2 Counters .............................................................................................. 16
6.2.1 Reset daily quantity counter ............................................................................ 16
6.2.2 Service counter ............................................................................................... 16
6.3 Filling level monitoring .......................................................................... 16
6.4 Test menu ............................................................................................ 16
7 Maintaining the machine ................................................... 17
7.1 Authorised maintenance personnel ...................................................... 17
7.2 Maintenance notes ............................................................................... 17
7.3 Lubricant .............................................................................................. 17
7.4 Maintenance schedule ......................................................................... 18
7.4.1 Daily maintenance........................................................................................... 18
7.4.2 Monthly maintenance ...................................................................................... 18
7.4.3 6-monthly maintenance .................................................................................. 19
7.5 Replacing the insulation stripping blade ............................................... 21
7.6 Replacing ferrule separating blade ....................................................... 21
2 We reserve the right to make technical modifications. Rittal electrical crimping machine R8 E
8 Troubleshooting ............................................................... 23
8.1 Personnel for troubleshooting............................................................... 23
8.2 Machine does not start ........................................................................ 23
8.3 Ferrules placed too deep in the transport unit ...................................... 24
Contents
8.4 Error messages .................................................................................... 24
8.5 Removing the wire end ferrule .............................................................. 25
EN
9 Machine decommissioning and disposal .......................... 25
9.1 Machine decommissioning ................................................................... 25
9.2 Machine disposal ................................................................................. 25
10 Electrical connection diagram .......................................... 26
11 Spare parts list and accessories ....................................... 27
Rittal electrical crimping machine R8 E We reserve the right to make technical modifications. 3
1 About this documentation
Warning!
Caution!
Caution!
Symbol
Meaning
Warning: dangerous electrical voltage
Warning: injury to hands due to sharp blades
Work may only be performed by a qualified electrician
Only perform work with personal protective equipment
Disconnect the mains plug
Notes on documentation
EN
1 About this documentation
The warnings in this documentation are structured differently depending on the
severity of danger.
Possible risk of fatality!
Notices with the signal word "warning" warn you about situations
which could lead to fatal or serious injuries if you do not pay attention to the notices specified.
Risk of injury!
Notices with the signal word "caution" warn you about situations
which could lead to injury if you do not pay attention to the notices
specified.
Property damage!
Notices with the signal word "attention" warn you about dangers which
could result in damage to property.
Situation-related warnings may contain the following warning symbols:
Additional formatting is used in the rest of the text which has the following
meaning:
4 We reserve the right to make technical modifications. Rittal electrical crimping machine R8 E
Note:
This constitutes information which is not related to safety, but
which provides important information regarding correct and effective work.
2 General safety instructions
This symbol indicates an "action point" and shows that you should perform
an operation or procedure.
– Bullet points are indicated with dashes.
2 General safety instructions
2.1 Intended use
The electrical crimping machine R8 E is an electrically-driven insulation stripping and crimping machine designed exclusively for insulation stripping from
flexible conductors in accordance with DIN 60228:2005 and the crimping of
"wire end ferrules on rolls" (0.5 – 2.5 mm²) on cable ends. For this reason, because of its construction, the machine has only this intended use.
For the intended use, the following must be observed:
– All notes from the operating instructions
– The documentation of the supplied products, as well as
– The notes for servicing/maintenance
Any other use is deemed improper.
The operational safety of the machine is guaranteed only for the intended use.
Only persons authorised by the manufacturer may perform changes, conversions and repairs to the machine.
Any safety-relevant changes or manipulations to the machine are prohibited. If
the operating company makes such changes or manipulations, safe operation
of the machines is not guaranteed.
The manufacturer accepts no liability for damage or consequential damages
that result because of the preceding measures.
Use only original spare parts and accessories authorised by the manufacturer.
The use of other parts voids the liability for any damage (also consequential
damages) that results from the use of other parts or non-authorised accessories.
EN
2.2 Not permitted
– Removing notification or warning signs.
– Opening the machine during operation.
– Using the machine with obvious defects or damage.
2.3 Machine dangers
A risk evaluation with subsequent safety inspection and safety acceptance was
performed on the electrical crimping machine R8 E. As for every machine,
some residual risks, that cannot be precluded because of design considerations, remain. See section 2.8 "Residual risks".
2.4 Operational hazards
The operator may rectify only those faults for which the housing does not need
to be removed.
2.5 Hazard sources
Before performing servicing, maintenance and cleaning work on the ma-
chine, switch off the machine, disconnect it from the power supply (e.g. cut
off the electricity supply, switch off the fuse).
2.6 Safety equipment
Safety equipment is installed to protect personnel. The operating company is
obliged to inspect the safety equipment annually.
Under no circumstances may safety devices be changed, removed or circumvented by changes to the machine.
Rittal electrical crimping machine R8 E We reserve the right to make technical modifications. 5
2 General safety instructions
EN
Safety devices
Function
Inspection
Housing
The housing may be
closed again.
Inspect for damage.
Safety switch
The safety switch is acti-
is opened.
By a qualified electrician.
LPV-100-24 switched-
The SMPS protects
may be present.
By a qualified electrician.
Symbol
Meaning
The protective earth is a measure that in the event of a fault protects
earth" measure is provided by the protective conductor.
removed only by service
technicians or qualified
personnel. Only for
switched-off state of the
machine. After removal of
the housing, ensure that
the earthing wire is inserted before the machine is
vated when the front flap
mode power supply
(SMPS)
against dangerous voltages, because not more
than 60 VAC or 110 VDC
2.7 Warning signs at and on the machine or components
– PE conductor connection: This marking is placed on the earth screw.
against dangerous touch voltage and electrical shock. The "protective
The connection is made via an IEC connector with leading protective conductor contact. The "PE" protective conductor (green/yellow insulating sheath only
in Germany) is used for these protective measures.
2.8 Residual XXX risks
Even when all safety and warning notes are observed, residual risks remain for
the machine operation.
The machine is state-of-the-art and built according to recognised safety regulations. Nevertheless, hazards for users or third-parties can result when operating the machine.
– The machine may be used only for the intended purpose.
– The machine must be in proper safety condition during commissioning.
– Faults that can impair the safety must be rectified immediately, whereby the
manufacturer may need to be contacted.
– For opened flap, access to the fixed blade is possible and so cut injuries can
result.
– Manipulation of the safety devices can cause the reoccurrence of the de-
scribed hazards.
2.9 Safety measures at the installation site
The machine must be placed stable on a table.
– There is a large hazard risk should a machine fall.
6 We reserve the right to make technical modifications. Rittal electrical crimping machine R8 E
2 General safety instructions
Note:
Target group
Operator
Technician
Transporting X X
Mounting X
Dismantling X
Setup
X
X
Operation X X
Cleaning X X
Maintenance X X
Repairs X
Inner-company instructions and checks should ensure that the
workplace and its vicinity remain clean and uncluttered.
2.10 Notes for the operating company
– The operating company is obliged to write operating instructions.
– The operating company is obliged to inspect the safety devices annually.
– Deploy only original fuses with the specified amperage.
– Knowledge of the local, operational safety and accident-prevention regula-
tions.
– All notes on machines must be kept legible, and renewed when necessary.
Notify the manufacturer without delay should defects become apparent, pro-
vided they were not caused intentionally.
Any imperfect machine parts must be replaced immediately.
2.11 Personnel requirements
The following target groups have different authorisations.
2.11.1 Operator
Requirements:
– Literacy skills
– Technical knowledge
– Instructed/trained
Knowledge:
– Machine function
– Intended use of the machine
– Machine safety devices
EN
2.11.2 Technician
Requirements:
– Rittal service technician
Work steps
2.12 Training and instruction
– Only trained and instructed personnel may work on the machine.
Rittal electrical crimping machine R8 E We reserve the right to make technical modifications. 7
3 Device description
EN
1 2 3
4 5 6
7
8
9
– Repair work may be performed only by the manufacturer or authorised ser-
vice departments.
2.13 Noise
The A-weighted equivalent continuous sound pressure level of the R8 E crimping machine is ≤70 dB(A).
Consequently, ear muffs are not required for operating the machine.
3 Device description
3.1 Overview
Fig. 1: Front view
Fig. 2: Connection circuit-board
8 We reserve the right to make technical modifications. Rittal electrical crimping machine R8 E
3 Device description
Electrical crimping machine R8 E
Conductor insertion length
40 mm
Wire end ferrules
0.5 – 2.5 mm²
Ferrule length
8 mm
Crimping form
Trapezoidal
Drive
Electric motor
Voltage
100…240 V
Frequency
50/60 Hz
Power consumption
100 VA
Fuse (mains filter module)
2 x T2AH250V
Degree of protection
IP 20
Protection class
I / PE conductor
Cycle time
1.8 s
Continuous sound pressure level
≤70 dB(A)
Dimensions (W x D x H)
288 mm x 349 mm x 230 mm
Weight
16 kg
Operating environment
Storage/transport temperature
-25 °C to +55 °C (short-term +70 °C)
Ambient temperature
+5 °C to 40 °C
Operating temperature
+10 °C to 45 °C
Max. operating altitude
2000 m above mean sea level
Humidity
50% at 40 °C (without dewing)
90% at 20 °C (without dewing)
Contamination level
2
Key
1 Belt roll
2 Roll holder
3 Flap
4 Touch display
5 Insertion funnel
6 Twist lock
7 ON/OFF power switch
8 Fuses
9 Mains plug
3.2 Technical data
EN
Rittal electrical crimping machine R8 E We reserve the right to make technical modifications. 9
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