HEAVY DUTY CRIMPING MACHINE

Type: HDPM/S-11

Manual

A version / 04-2013

UNIMATIKA Ipari Irányítástechnika Kft.

UNIMATIKA Industrial Control Engineering Ltd

Budapest, Hungary
HEAVY DUTY CRIMPING MACHINE MANUAL

This plan documentation is the intellectual product of UNIMATIKA Ltd. It is FORBIDDEN to copy, hand over its data without
the consent of UNIMATIKA.

CONTENT

INTRODUCTION 3
TECHNICAL DESCRIPTION 3
1. DESRIPTION OF UNIPRÉS CRIMPING MACHINE 3
1.1. Construction of UNIPRÉS 3
1.2. Technical characteristics 3
1.3. Safety settings, regulations 4
2. DESCRIPTION OF UNIPRÉS UNITS 7
3. OPERATION OF EQQUIPMENT 7
4. HANDLING INSTUCTION 11
4.1. Switcing on and operating of machine 11
4.2. Handling and operation instruction 12
4.3. Maintenance and repair instruction 15
5. SAFETY ENGENEERING PRESCRIPTIONS 17
6. LIST OF PARTS AND MATERIALS 18

FIGURES
HDPMS11-KV_A UNIPRÉS schematic drawing
HDPMS11-RI01_A Scematic drawing of electrical elements and cabling
HDPMS11-RI02_A Scematic drawing of actuation and safety system
HDPMS11-HS_A Hydraulic supply and control system
HDPM-HO1_A Hydraulic operation principle
HDPMS11-KI01_A Arrangement of NPvsz control cabinet
HDPMS11-AK01_A Connection drawig of electrical elements of HDPRES
HDPMS11-TK01_A, Connection drawig of power supply of NPVSZ cabinet
-TK02_A
HDPMS11-KV_A Deaeration of proportional valve
Figure 1 Crimping pressure-time diagram
HDPRES signalling
PLC signal list

ENCLOSURES

Enclosure No. 1 Detailed description of electric control unit of type UPVE 2-125/16
Enclosure No. 2 Description of supervisory control program

REGISTRATION OF DOCUMENTATION AND PROGRAM CHANGEMENTS

Characteristics of version Mark of Date of ver- Applied program version

version sion
VISION PLC
Base version A 18-03-2013 WNP405 v1. Npres 417

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HEAVY DUTY CRIMPING MACHINE MANUAL

INTRODUCTION
Heavy duty crimping machine of HDPM/S-11 type (hereinafter: HDPRES) is a single-purpose
machine suitable for crimping wire clips requiring high pressing force (max. 30 t). Its maximum
hydraulic pressure is 160 bars. Owing to its important feature, double working cylinder head
design, it can ensure both quick and heavy-duty operation. The crimping cycle time can be re-
duced significantly by quick tool closing.
The clip press is suitable for operating such SEREC or compatible tools whose distance of the
dangerous point from the plane of the light curtain is greater than 270 mm when the tool is in-
stalled in its place.
This description includes basic information on the construction, operation, handling and main-
tenance of the equipment.
Operation of the clip press is permitted only if the safety engineering rules described in the ma-
chine manual are observed.

Designer and constructor of the system:

UNIMATIKA Ipari Irányítástechnika Kft.
(UNIMATIKA Industrial Control Engineering Ltd)
Address: H-1097 Budapest, Bárd u. 5.
Tel/Fax: 00-36-1-215-8829, 00-36-1-215-8228
E-mail address: unimatika@unimatika.hu

Responsible designer: György Dózsa

1. EQUIPMENT CONSTRUCTION, TECHNICAL DATA

1.1 Construction of the crimping machine
The equipment’s main elements and important dimensions can be seen in the drawing marked
HDPMS11-KV. The tool block combined with the working cylinder (hereinafter: pressing ma-
chine) is placed on the large work-tables (having the same ergonomic design as the SEREC
equipment). The work-table is equipped with guard. The following main elements are located
on the work-table or in the space below it.
On the work-table:
- tool block combined with the working cylinder (hereinafter: pressing machine)
- display and handling elements necessary for the handling
- guard with the light curtain
- data collecting and displaying computer
In the space below the work-table:
- hydraulic power and control unit
- pneumatic supply and actuating elements
- electric control cabinet
- safety control system elements

The equipment’s electrical system-technical design and the cable diagram are shown in the
drawing HDPMS11-RI-01.

1.2 Technical characteristics

Hydraulic actuating pressure in impulse mode, with 50% fill: 10-140 bar
Pneumatic actuating pressure: 6 bar
Supply voltage: 3 x 230/400 V 50Hz

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HEAVY DUTY CRIMPING MACHINE MANUAL

Maximum electric power requirement: 3 kW

Average power consumption: 1.2 kW
Contact protection: protective earthing
Overall dimensions (width x height x depth): 2000 x 1230 x 1875 mm
Weight: 340 kg
Height protected by light curtain measured from the work-table plane: 30-710 mm
Distance between the light curtain plane and the press centre: 290 mm

The technical data given are values set by the manufacturer (in case of adjustable parameters).

1.3 Safety settings, regulations:

Distance between the light curtain and dangerous pressing point, minimum: 270 mm
Size of gap not protected by the light curtain above the work-table, maximum: 30 mm
(maximum distance of the lower beam of light curtain from table plane)
Maximum value of pneumatic actuating pressure: 6 bar

2. A EQUIPMENT MAIN UNITS AND THEIR TECHNICAL CHARACTERISTICS

Work-table – pressing machine

The pressing machine is a hydraulic press designed for this purpose, manufactured by the Bar-
abás Mérnökiroda Kft (2220 Vecsés Kinizsi u. 8.). The pressing machine has guide-column
design.
The working cylinder features double working head design.
Pressing cylinder dimensions: D1= Ø 150, D2= Ø 70
Piston rod dimension: d= Ø 50

The press seats on the load-bearing cross-brackets formed on the work-table. Surface of the
work-table is covered with stainless steel sheet.
In order to indicate proximity of the moving tool face to the clip (speed change position, herein-
after SVP), the pressing machine includes a position indicator switch. This switch has double
function: changes the working cylinder speed and disconnects the light curtain protective func-
tion when the switching position is reached. Because of the latter function, the switching circuit
has safety design.
The speed change is done with the hydraulic directional valve marked HSZ2. The press per-
forms slow motion in normal position of valve, while quick motion in its controlled position.
Displacement of the moving tool face (stroke) is limited by the working cylinder’s end faces. Its
maximum value is 65 mm till the upper end position (FVH). The stroke of the press can be set
(reduced) with the inductive proximity switch setting the upper normal position (FAH). During
the normal crimping mode, the press opens till the upper normal position. By this the press can
be spared and the working process can be accelerated (by adjusting the necessary shortest
stroke).

Tool block’s technical data:

Distance between the tool holder faces (dimension Z): 154.4±0.1 mm
Range of speed change position setting: 7.5 mm
Maximum stroke of the tool (till the upper end position FVH): 65 mm
Range of tool stroke adjustment (till the upper normal position FAH): 52-62 mm

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HEAVY DUTY CRIMPING MACHINE MANUAL

Hydraulic supply and control unit

The pressure necessary for pressing the terminal is supplied by a hydraulic power unit.
The schematic circuit, assembly drawing and main dimensions of the power unit can be seen in
Figure HDPMS11-HS1_A. The principle of hydraulic hydraulic operation shown on Figure
HDPM-HO1_A.
The constant-volume-flow-rate value pump is driven by 3kW, 3-phase asynchronous motor.
The hydraulic resistance of the circuit and thus the output pressure of supply unit is regulated
by continuously controllable pressure limiting valve marked PC1 installed in the bypass branch.
The pressure limiting valve is controlled by outgoing current of the valve controller marked VC
in the plan. The valve controller receives its input (control) signal from the analogous outgoing
channel of the PLC.
In normal status (pump is turn-on but is not crimping), the power supply heat production is low
because the circuit resistance is significantly reduced by the idle valve (HSZO) installed in par-
allel with the pressure limiting valve.
The 4/3 directional control valve applies the actuating pressure to the working cylinder. With-
out controlling (in neutral position), the directional valve blocks the movement of the working
cylinder.
Actuated electrically, the directional control valves are controlled by PLC through the 4-chan-
nel power switch (PS).
The oil pressure is detected by the pressure transmitter (PT). (The 4-20 mA pressure-propor-
tional current sign is transformed into 2-10 V sign and connected to the PLC analogous input).
The control elements (HSZ1, HSZ0, PT1 and PC1) are installed in a manifold designed and
manufactured individually for this purpose. The assembly drawing and overall dimensions of
the manifold can be seen in Figure HDPMS11-HS1_A. Crimping tool working cylinders are
connected to the hydraulic manifold through rubber conduit equipped with quick release cou-
pling.

Hydraulic power unit main technical data:

Output pressure: 10-160 bar
Flow rate: 14 litre/min
Expectable noise level: <64 dBA
Operating temperature of oil: <60 °C
Tank volume (till the centre of level indicator) 50 1

Pressure transmitter technical data:

Measuring range: 0-160 bar
Output signal: 4-20 mA
Accuracy: 0.5 %
Connection: G1/2”

The system can be operated with mineral oil based working fluid (HL and HLP type).
Viscosity: 22...32 mm2/s [CSt], at 40 °C temperature

Pneumatic supply and actuating elements

The terminal and wire clamping is carried out by aair operated cylinders . The wire fixing tool
tool – 1 pc per machine – is supplied as accessories .
The terminal feeding may happen by hand or – at rowed terminals – by pneumatic cylinder.
The working cylinders are operated, by one 4/2 way electric-pneumatic directional control
valve each.

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HEAVY DUTY CRIMPING MACHINE MANUAL

The feeding air supply occurs through the air service unit containing filter, regulation reducer
and oiler. The drainer of the condense water is hand-operated.
The pneumatic system is separated from the central air network by a hand-operated closing
valve.
It’s more important technical data:
pressure of feeding air: 16 bar (maximum)
output pressure regulated: 2 to 14 bar (adjustable)
performance: 700 l / min
filter fineness: 40 microns
Pneumatics oil qualities recommended for the oiler:
FESTO pneumatics oil 23 cSt
SHELL TELLUS 15 22 cSt

Electric control cabinet (NPVSZ)

Electric control cabinet consists of

- distribution and fuse circuits of 0,4 kV and 24 V power supply
- PLC with its interface circuits
- start, protection and signalization circuits of drive motor for hydraulic pump.

In electric control cabinet, the terminal blocks of connections of feeding, control and signaling
cables as well as the collecting bus of common earthing of contact protection can be found.
Its more important technical data:
summarized energy consumption: maximum 4 kW
power supply of auxiliary circuits, signaling lamps
and supply of directional control valves: DC 24 V
protection of UNIPRÉS crimping machine: IP54

Elements of EPVSZ cabinet and their arrangement in Figure HDPMS11- KI01, connecting of
them in Figures HDPMS11- AK01, - TK01, - TK02 can be seen. More information about opera-
tion, maintenance of electric distribution and control unit can be found in. Supplement 1.

MKR connection cabinet

In t he MKR signal junction box security control elements and cable connection terminals are
located. The elements of cabinet is connected as shown in Figure HDPMS11- AK02.

VISION supervisory control system

The brain of Equipment is an IBM compatible PC which, with operator's assistance, controls
and supervises the crimping process.
Its more important tasks:
- under operator command, loads the parameters required to controlling the process from
the database into PLC
- displays the state of process and the basic control data (parameters)
- stores data characterizing the state of UNIPRÉS crimping machine and ready splices
- qualifies the last splice
- it allows editing of databases, checking, adjusting of hydraulic control system,
deaereating of system and checking and calibrating of height measuring system.
- interprets, displays and logs the error arisen

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HEAVY DUTY CRIMPING MACHINE MANUAL

Certain services, functions of supervisory control system can be used just by authorized persons
knowing the password. Operator tasks connected directly with the producing can be carried out
also without password.

Actually, the process control is performed by PLC receiving the basic control data from PC
through serial line. The data transfer is done via RS232 serial line.

Safety devices
Operator safety is ensured with the guard preventing entry into the dangerous space and the
light curtain watching entry into the working space on the operator side. Height of guard is 800
mm above the work-table.
The light curtain belongs to safety category 4, it is 700 mm high, suitable for detecting hand
(Ø30 mm). The light curtain will not detect entry of an object (wire) smaller than Ø 10mm. The
light curtain is installed in such a way that the protected plane starts 30 mm above the work-
table. This 30 mm gap ensures that longer wires hanging down from the work-table can be led
into the working space.
If entry into protected space occurs during closing of tool prior to achieving the speed change
position (SVP), then the light curtain controlling unit will disconnect the hydraulic valve con-
trolling the closing (HSZ1_LE ) from the supply voltage and stop tool movement.
The speed change position is a safety tool position at the same time because it is the position of
the tool when the tool approaches or reaches and bends the clip to such extent (the gap is so
small) that it is not already possible to put finger into the dangerous space. This safety position
is detected with the safety position switch.
After reaching the safety position (in the following phases of the pressing process) work per-
formance is already permitted in the working space behind the light curtain.
As an additional protection, working process start is possible only with two hands, that is, the
operator must press two press buttons simultaneously, within 0.5 sec.

EMERGENCY STOP
In case of actuating the emergency stop button, the control system will disconnect the actuating
valves from the supply voltage and stop the hydraulic pump. The schematic circuit diagram of
the electric actuating and safety elements can be seen in the drawing HDPMS11-RI-02.

Handling and display elements

Operator is informed about the tasks with the green OPERATION ENABLED, and the red
ERROR lamp. Both lamps have been installed on a bracket behind the tool in a well visible
place.
The emergency stop button can be found on the right side of the work-table, in the part next to
the operator. The start press buttons are found on the front side of the work-table about 300
mm distance from each other.

3. OPERATION OF EQUIPMENT
The equipment will operate in accordance with the selected operation mode. The operation
mode is selected in the supervisory control system. Basic task of equipment is to manufacture
clipped electric connections (hereinafter: crimping point). Its further operation modes and ser-
vices facilitate preparation, evaluation and logging of crimping as well as operation and main -
tenance of equipment.

HDPRES ready to operate status is achieved when

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HEAVY DUTY CRIMPING MACHINE MANUAL

- the supply voltage has been connected

- the hydraulic power unit (hydromotor) has been switched on.
The equipment reaches pressing enabled status when
- the crimping point has been selected in the supervisory control system
- the terminal has been fed and/or fastened (hereinafter: terminal preparation)
- the wire has been placed and fastened.

The operator is notified of it with ENABLE green light. The pressing process can be started by
pressing START1 and START2 start buttons simultaneously (two-hand actuating).
Depending on the properties of tools, working process can be of type 0, 1, 2 and 3. The working
processes differ from each other in the terminal preparation.

Process type 0
After placing the clip by hand, by pressing multi-function (pressing start / terminal fixing / ter-
minal feeding / terminal bending) START1 press button (PSZ1 pneumatic valve operates), ter-
minal is fastened which will last till the end of the crimping phase.
Select it for a tool designed for individual terminals fed manually.

Process type 1
When pressing START1 press button, the terminal is forwarded by actuating the pneumatic dir-
ectional control valve and working cylinder for 1.5 sec. When the time passes, the working cyl-
inder stands in normal position and the feeding device fastens the terminal in pushed-in posi-
tion.
Select it for a tool designed for rowed terminals and equipped with terminal feeding device.

Process type 2
Neither terminal fixing, nor terminal feeding is done for the process so the START1 press but -
ton does not affect its operation.
Select it for a tool designed for individual terminals fed manually and requiring no fastening.

Process type 3
Neither terminal fixing, nor terminal feeding is done for the process so the START1 press but -
ton does not affect its operation. Following the process crimping phase, terminal bending is
done with the parameters set to control the bending.

Process type selection and together with the change of START1 function takes place automatic-
ally in accordance with the value (0 / 1 / 2 / 3) of the process identifier (P_type) found in the
tool data base.
Following the two-hand start of pressing, the pressing process phases 2-6 run automatically,
with the parameters sent from the supervisory control system after selection of crimping point.
Following Phase 6 – height measurement, the process will continue in accordance with the
evaluation of the measuring results.
In case of OK, the process proceeds with Phases 7-8 – tool opening. After reaching the open
status, the supervisory control system sends the new height evaluation limit values to the PLC,
which then enables the pressing.
In case of NOK terminal, the tool remains closed and, after acknowledgment on computer,
reaches the open normal position only by two-hand start.

In the following, the pressing process will be described in details in accordance with the at-
tached control cycle diagram (drawing no HDPMS11-RI-05). We indicated the control para-
meters important for the process sequence for each partial control process (process phase).

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HEAVY DUTY CRIMPING MACHINE MANUAL

1. Crimping process preparation

After completing clip fixing / clip feeding as detailed above, operator’s next task is to place and
fix the wire.
Wire fastening is done with press button WIRE FIXING found on the work-table in the vicinity
of tools. Through the input, PLC controls the actuating pneumatic working cylinder in such a
way that one pressing results in grip, while the other pressing in release.
If wire fastening is done and the following conditions exist:
- the supervisory control system is in pressing status (operator’s main screen displayed)
- terminal fixing (for Process type 0) / terminal feeding (for Process type 1) has been done
- there is no hindrance in the light curtain protected plane,
then ENABLE green light shows to the operator that the crimping can be started. Crimping pro-
cess starts by two-hand operation – pressing the press buttons within 0.4 sec. Further steps of
process performed automatically are as follows:
2. Tool closing with maximum speed till reaching the speed change position (SVP)
The position indicator switching point must be set in such a way that the change of speed
(and at the same time pressing force) is done 2-3 mm before reaching the wire pressing pos -
ition. When the set Te feeding time elapses, the speed change occurs even if SVP signal
does not arrive to the PLC input (e.g. in case of failure or wrong setting of the position in-
dicator switch).
When reaching the speed change position, the process will proceed with Phase 3 (even) if the
speed change is disabled, but speed change will not occur.
Pe stroke pressure: tool dependant, adjustable value.
Te stroke time: tool dependant, adjustable value.
In order to achieve maximum closing speed, Pe value must be adjusted in such a way that its
value is greater than the friction pressure of the working cylinder.
3. Tool closing with reduced speed
Pz impact pressure: tool dependant, adjustable value.
Period: 200 msec programmed permanent value
4. Terminal crimping till Pv increased continuously during the Tv period.
The crimping is finished and process continues with the next phase,
- when the pressure reaches the set value or parameter Pv
- the TV crimping time up to a maximum value of 2 sec (even stop when the pressure is
below the set value Pv )
Pv crimping pressure: terminal dependant, adjustable value.
Tv crimping time: terminal dependant, adjustable value
5. Relaxation
During this step, Pv pressure value decreases to 9 bar constant (fixing) pressure value during
the 600 msec relaxation time which is also constant. During the process, the terminal aprings
back and takes its final height.
For the process type 3 with clip bending, the terminal bonding point is fastened during the
relaxation and height measurement in the tool with the Pr pressure adjustable as tool para-
meter.
6. Height measurement
Following the relaxation, PLC is continuously measuring the splice height. The splice height
is the last measured value the difference of which from the previously measured value is less
than 15 μm. If this condition is not fulfilled after T6 = 1 sec, then the process will continue
through the error line. Incorrect height, impossible data or missing height data will also res-
ult in error line operation.

In case of proper height within the tolerance, the process will proceed with the following
phase.

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HEAVY DUTY CRIMPING MACHINE MANUAL

7. Crimping tool opening with maximum speed

Opening pressure: 2.5 x Pe, but the programmed minimum value of it 20bar.
Te opening time: the same as in Phase 2.
Tool opening is done with the greater speed in the whole opening phase.
8. Crimping tool opening with lower speed (pressure)
Pz closing pressure: tool dependant adjustable value.
Period: 300 sec fix programmed value.
The process ends when the new height evaluation limit values are downloaded to the PLC
from the supervisory control system. The default time set for it is 4 sec.

Following Phase 1 preparation, steps of crimping process (Phase 2 - 8) are the same for pro -
cesses 0, 1 and 2. Steps of Process 3 different from the above are as follows:
- After Phase 4 crimping, clip bending is done. Clip bending is performed by a pneumatic
working cylinder actuated by the PSZ1 directional control valve. Start and end of bending
phase can be set by the times Tk and Th (this process type used only at Lear Gödöllő plant).

CONTROL PROCESS IN CASE OF FAULTY CRIMPING

PLC evaluates the process on the basis of measured height and maximum crimping pressure
(Pmax). Result of evaluation will appear on the display for the operator.
Crimped wire is qualified faulty and keep fixed (blocked) in the tool in case of:
- wrong height
- incredible height and
- no height data.
The height is wrong (NOK) if the height dimension of the crimped bonding point is beyond the
limit values calculated from the nominal height (Hn) and the relevant tolerance values (TOLn),
or the average height (Ha) and the relevant tolerance values (TOLa).
Incredible height error occurs if the difference of consecutive measuring values is greater
than15 μm till the measuring time expires (max 1 sec).
The system indicates pressure error if the measured maximum crimping pressure differs from
the specified Pv value by more than ± 5 %. After acknowledgement in the supervisory control
system, the process can be continued by two-hand start. By this, steps 7 and 8 of the crimping
process (tool opening) are performed.

OPERATION OF THE SAFETY SYSTEM

If entry through the light curtain into the working space occurs during the crimping process
while the tool closing prior to reaching the safety position of the press, then the control system
will interrupt crimping process. It is done by disconnecting HSZ1_LE directional control valve
from supply voltage (UP1). Voltage supply disconnection results in stoppage of hydraulic
working cylinder movement and termination of wire fixing.
Status of clip fastening / clip feeding working cylinder does not change because it is operated
by the UB1 supply voltage, directly from the PLC output. Crimping process interruption is in-
dicated by blinking red light of the workplace error lamp. Following the interruption, the crimp-
ing process can be continued as follows:
- After error status acknowledgment and repeated fastening of the wire, crimping is enabled
and can be restarted with two-hand start.
For simple and quick handling, the error acknowledgement takes place by pressing the
multi-function START2 press button (crimping start, error acknowledgement).

After reaching the SVP safety (and at the same time speed change) position, it is allowed to per-
form work in the protected space. It can be achieved by muting the prohibition function of the

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HEAVY DUTY CRIMPING MACHINE MANUAL

light curtain during the existence of SVP signal. The muting signal is switched to the control in-
put of the light curtain by the BR3 safety relay. BR3 safety relay is actuated by the safety posi-
tion switch used for indicating the SVP position. (When the switching position is achieved, the
safety position switch gives closed contact signal to the safety relay. The PLC receives signal
that is closing contact in normal position from the same safety relay; when the SVP switching
position is reached, the PLC input signal will be “break”.)
In order to ensure safety operation, the switching position must be set in such a way that the
pressing punch can approach the terminal in 2-3mm distance, while in case of fork-type ter-
minal can reach and bend the terminal (but only to the extent that the wire pressing does not be-
gin).
The switching point depends on the terminal; checking of the switching position, and, if
necessary, adjustment of Speed Change Position Switch (SVPK) must be performed after
each tool change.

4. HANDLING INSTRUCTION, KARBANTARTÁS

4.1 Switching on and operating of crimping machine

The description focuses on the more important tasks that should be performed when the in-
stalled base by relocating production facilities .
Before electric switching on the crimping machine, it should be checked whether the earthing
for contact protection is connected up carefully, the uninterruptedness of protecting earthing
network exists, the connecting up of connection points have the proper quality (no breaking,
goodness of bonds).

By turning on the power supply network MAIN SWITCH and the circuit brakers F1, MV the
crimping machine gets under voltage.
The switching on order and tasks of fuses are as follow:
- Circuit braker F1 protects the circuits of PC and 24 V power supply unit, after switch-
ing on, the green light of PLC SUPPLY ON lamp lights and PC gets under supply-volt-
age.
After its switching on, check the oprability of emergency pushbuttons
- Through three-pole motor protecting braker MV, the main circuits of pump motor get
under supply-voltage and, after switching on the motor, the red lamp PROTECTION
OPERATED goes out.
By means of a short time (1 to 2 s)operation of electric motor, make sure the rightness of
direction of rotation. The direction of rotation must be clockwise seen from the fun side
of motor.
Before starting up the hydraulic unit, it is necessary to check
- the oil level of hydraulic supply unit
- the correct joining of pipe lines and the tightenedness of joints

ATTENTION!

In beginning of trial-run operation, the sealed of hydraulic system must be checked with low
pressure load. The low pressure check can be made by handy actuating of valves HSZ0, HSZ1
and HSZ2.
When being of high pressure load (crimping cycle, test operation mode), it is vorbidden to
tighten or loosen the components, screws, or pipe joints of pressure circuit
In danger situations occurring during trial-run operation, equipment must be switched off. It
may be switched on anew just after the danger situation elimination.

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HEAVY DUTY CRIMPING MACHINE MANUAL

***

Proper operation of the equipment must be vented to (deareate) the hydraulic system.The
deaerating of connecting hoses occurs by means of circulation of oil and, at the same time, by-
passing of hoses of working cylinders. The process can be started from the supervisory control
system in DEAERATING operation mode.
Deaerating of elements of manifold occurs by means of loosening of threaded joints of pressure
gauge and pressure transmitter as well as remove the cup on the highest point of proportional
control valve and of pushing out the air by oil pressure. The 6 to 8 bar oil pressure can be pro-
duced by handy operation of HSZ0 valve or in pressure test operation mode (the value of P1 to
P5 is 10 bars).
Instruction to the deaerating of proportional control valve is given by Fig. 7. The deaerating
must be continued until the oozing oil becomes bubble-free.
After tool replacement or long time stand-by, it is expedient to carry out the deaerating anew.

After deaeration valve controller, the pressure characteristics regulation should be carried out
by the help of UI 904 potentiometers Imin (for adjusting the pressure zero point) and Imax (for
adjusting the pressure range).The valve controller can be found in the electric control cabinet
(NPVSZ). Adjusting should be carried out when the supervisory system is in PRESSURE
TEST mode. For taking the characteristic, the following pressure values are recommended: 15,
25, 40, 60 and 80 bar. The exact value should be set at 25 and 60 bar. After having adjusted the
current output, the affects of that adjusting should be checked by taking characteristic anew.
This adjusting should be repeated until the desired function will be achieved. After some crimp-
ing actions, this checking should be fulfilled again.

P1: 15 bar
Frontplate of
P2: 25 bar O Imax VC valve controller
P3: 40 bar + -
P4: 600 bar
P5: 80 bar Imin
+ -

Next step is checking of presure curve, the pressure-time diagram of crimping process. The
pressure behavior curve is correct if
- the pressure drop characterizes the slow motion of cylinder can be well seen after boost
time Te elapsing
- the collosion point (erased when the moving anvil reach clip) can be detected at the end
of slow moving (feeding) phase or at begening of 4. phase (crimping)
- the pressure peak arising at collosion is fairly low consequently there is no precrimping

In the curve markers (zero peak pressure drops) indicate thespeed change (m1) and height mea-
surements (m2, m3) time points to help the correct adjustment.
Except the extreme cases, you can reach the correct setting by the help of modification of pa-
rameter Te.
In beginning of trial-run operation the sealing of pneumatic system must be checked.

4.2. Handling and operation instruction

Normal operation
Crimping machine prepared according to the instruction of putting in service or having been al-
ready in operation, is ready for operation
— after switching on the power supply voltage (position 1 of MAIN SWITCH) and

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HEAVY DUTY CRIMPING MACHINE MANUAL

— after starting up the pump motor.

ATTENTION!

The safety requirements relating to operation must be kept as follow the hydraulic equipment
must not be operated then, if
— any of hydraulics components gets out of order,
— an alarm signal is actuated,
— the pressure measurement does not function,
— the pressure exceeds the allowed limit,
— the oil temperature exceeds the allowed value or
— equipment emits sound relating to failure
In the course of first switching on, the red color lamp ERROR situating on the workplaces
lights warning that equipment is not ready for operation because PLC have not got the crimping
parameters yet.
After crimping point slection, the parameters load and the crimping machine gets to the state
ready for operation, what will be signalized by green lamps operation ENABLED.
In the course of producing, the operator is informed by the signaling lamps. In the case of green
light, it is allowed to start crimping and in the case of red light gains information, for further
tasks, from the screen of the supervisory system.
On the screen can seen the following database data
- name and drawing of crimping point
- data of crimping tool
- heights data (maximum, minimum, nominal values)
Measured and calculated data of the last splice produced
- hold pressure
- height, average height value
- reading operating cycle counter
and data relating to operation mode and error states of equipment.

The interventions of operator as well as the errors arising are fixed by the log of events. Error
messages are displayed on the screen in window. The log of events can be activated from menu
items or scan codes.
In the case of crimping machine fault, fault elimination should be fulfilled.
The quality of produced splice is guaranteed by splice height within the tolerance.
If you want to appoint the cause of height error as well as pressure error, an important aid is for
you the knowledge of pressure behavior curve. You can select the pressure curve in the bottom
menu line.
In the case of height error, you should first check whether the setting of terminal dependent pa-
rameters Pv, Tv, SVP are correct, if necessary, you should correct them. In the case, if some
height error remains, you should modificate the machine depending parameters. The view-
points of setting can be found in point 3.1.4. of Handling instruction. The operation is not en-
abled also then when there is fault in the system. Fault is signalized by red lamp ERROR.

Equipment faults
- pump motor is fallen out (PROTECTION HAS BEEN ACTIVATED)
- supply-voltage UP1 is fallen out.
- emergency activation has happened

or crimping faults (concerning one of the workplaces)

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HEAVY DUTY CRIMPING MACHINE MANUAL

— pressure error *
— NOK height *
— incredible height data*
— no height data

Pressure error arises if the value of hold pressure (Pv) differs from the prescribed value more
than 5%.
The height is wrong (NOK) if the height dimension of the crimped bonding point is beyond the
limit values calculated from the nominal height (Hn) and the relevant tolerance values (TOLn),
or the average height (Ha) and the relevant tolerance values (TOLa).
Incredible height error arises, if measure is not ready during measured period 1 sec. Measure is
ready and measured value is accepted if difference of measured values equal or less than 15 μ.
No height data error arises then, if no measured value arrives into PLC.
In the case of faults/errors marked with *, operation can be continued after their acknowledg-
ment.

If the crimping cycle, due to crimping machine fault (pump motor coming to a standstill, etc.)
or emergency activation is interrupted, the crimping tool can remain in a state (stuck state) dif-
fering from the basic one. Such state can arise in the case of power cut too. Steps made for
elimination of stuck state:

- in the case of emergency activation: fault elimination, resetting of push

button bolted, logging
- in the case of crimping machine fault: fault elimination, logging

If we want the crimping tool to take its basic position, we have to start a new crimping cycle by
means of carrying out the above mentioned steps.
IMPORTANT! After returning of supply-voltage, it should be checked whether, mainly in the
individual workplaces, the last state of period before power cut will appear!

AFTER POWER CUT, IT IS EXPEDIENT TO MAKE SELECTION IN EVERY CASE!

Handling of supervisory control system

Assortment of services provided by the supervisory control system can be accessed from the
main image by clicking of menu items at the workplaces by means of mouse.
Assortment of services are accessible in the case of knowing of password, except the selection
of splices and splice sequences belonging to operator activities for which no key-words are nec-
essary.
After returning to the main image, the validity of password comes to its end automatically.
- pointing at it by mouse
- clicking it by left key of mouse
- entering the password from keyboard
After this, a new window appears on the screen where the further handling is to be carry out ac -
cording to descriptions of individual menu items.
Their detailed description can be found in the Supplement 2.descripting the supervisory pro-
gram.

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HEAVY DUTY CRIMPING MACHINE MANUAL

4.3. Maintenance-and-repair instruction

Ordinary maintenance - hydraulic supply unit

Checking of hydraulics oil quantity

Check the quantity of hydraulics oil in every month.
In the case of low level, fill up the oil tank. Check the impurity, decrement of hydraulics oil in
the case of every filter replacement. It is recommended to change the hydraulics oil after every
5000 to 6000 hours run in any case. During the oilchange, it is expedient to clean the oil tank
too.

Checking of hydraulics oil temperature

The hydraulics oil temperature must not be higher than 60 oC even in the case of continuous
operation. It is expedient to check the hydraulics oil temperature every week.

Checking and replacing of filter

Replacing of filter falls due when the no-load running pressure increases by 1 bar in compari -
son to value belonging to the start. In other cases, it is enough to carry out filter replacement in
every 1000 hours run or every quarter of year.
Type of filter: Armafilt 0-109/110.1 as well as any other equivalenting car oil filter.

Checking of noise level

In the case when noise level of UNIPRÉS crimping machine is higher then the allowed one, the
hydraulic system should be deaerated. If the noise level will not decrease in consequence of
deaerating, one have to turn to special service.

Checking of pressure characteristic

A checking of pressure characteristics in test operation mode should be carried out every quar-
ter. If the difference from the nominal pressure is higher then 2 bar in P2. P4 set points, the
valve controller should be regulated. The regulation should be carried out according to chapter
4.1.

ATTENTION

When repairing the equipment, before disassembly of hydraulic equipment,

- switch off the Main switch and
- ensure the protection against accidental switching on.
After any disassembling of hydraulic equipment, the putting into operation must be carried out
in accordance with safety requirements of trial-run operation.
* * *
Maintenance of electric control system
Details of this electric unit are elements of high reliability and of long operation life, therefore,
they do not require special maintenance, only recommended periodic monitoring of the
emergency stop circuit .

Continuous test for fault and error signalizing

PLC and PC carry out test operation in every workcycle and, in the case of error, they fulfill er -
ror handling. The supervisory control system signalizes the error and records it in the log of
events with fixing its time and, in the case of certain errors, disables the further operation.

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HEAVY DUTY CRIMPING MACHINE MANUAL

DESCRIPTION OF EVENT KJ ES MT
UB1 supply OFF error + + +
Crimping pressure error + + +
NOK height + +
No height data + +
Incredible h.data + +
Hydromotor fallen out
Communication error + + +
Program start - program stop +
Entering the menu item +
Init error +
PLC merged error +

Legend: KJ: displaying on the screen ES: logging of events MT: operation disabling

Causes of errors and their elimination

UP1 supply error

Cause of error
- In consequence of short cut of supply-voltage UP1, fuse B1 has blown
- relay J1 is contact damaged or its circuit signaling the state is broken
Error can be corrected by elimination of short cut, replacement of part, repair of circuit
out of order.
Crimping pressure error
Cause of error
- Characteristic of pressure limiter deviates from the specified value
- The pressure limiter or its control loop is out of order
- Pressure limiter or its signal processor loop is out of order.
- Pressure limiter or hydraulic supply line contains air
Errors can be eliminated by
- adjusting of pressure limiter in test operation mode
- Repair or replacement of faulty details
- Deaeration of hydraulic supply line and pressure limiter (according to the descrip-
tions of section 3.1. Commissioning)
NOK height
Cause of error
— crimping pressure error (see causes above)
— not proper value of splice dependent parameters
— the height measuring is no verified one
— failure of microwatch
Elimination of error:
— elimination of crimping error occurs according to ways mentioned above
— correction of splice dependent parameters
— calibration
— replacing of microwatch
Incredible height data
Cause of error
– vibrate of pressure, in the system is air
– Microwatch shows negative value
Elimination of error:

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HEAVY DUTY CRIMPING MACHINE MANUAL

– Exhausing
– Microwatch checking, setting.
There is no height data
Cause of error
— microwatch is out of order, it is switched off, its battery is run-down
— error connected with interface, cable, connection
Errors can be eliminated by
— replacing of microwatch, switching on it, replacing of battery
— replacing, repair of parts

Causes of errors of workplace 2 and their elimination are identical with that of workplace 1 but,
where appropriate, the circuit elements serving the workplace 2 should be taken into considera-
tion. In this description, the reference to the workplace 2 figures in bracket.

Errors of operation of equipment

HYDROPUMP STANDSTILL
Cause of error:
— main circuit of pump motor is out of order
— motor starter auxiliary circuit error
— electrical or mechanical error or overload of pump motor
Elimination of error by:
— replacement of faulty elements of supply network, adjusting of motor pro-
tecting circuit
— repair of motor starter auxiliary circuit, replacement of faulty details
— replacement of motor out of order.
EMERGENCY SWITCH ON
Cause of error signalization:
— EMERGENCY STOP has been activated in one of workplaces
Elimination of error:
— after elimination of circumstance causing the emergency, the push-button
EMERGENCY STOP can be unbolted. After acknowledgment of error, the
equipment gets into basic state. If, in the course of emergency stop, the
crimping cycle was interrupted, the crimping tool can be brought into basic
position by starting of a new cycle.
PLC guarding battery error
The fact that the voltage PLC guarding battery is low is signalized by red LED BAT-
TERY and this state is recorded by log of events.

5. SAFETY ENGINEERING PRESCRIPTIONS

In the course of designing and manufacturing of 2-125/16 type UNIPRÉS crimping machine,
the manufacturing company took into consideration the requirements of Standard EN 60204.
Equipment meets the safety requirements referring to the safety of equipment and electric com-
ponent parts of machines.

In accordance with requirements of Standard IEC 536, the electric safety and contact protection
classification of HDPMS-11 type crimping machine is CLASS I..

Contact protection is realized by the CLASS I. POTENTIAL EQUALIZER NETWORK (PEN

IEC 364-5-54) wich is connected to the PE conductor (IEC 364-3) in one point.

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HEAVY DUTY CRIMPING MACHINE MANUAL

Thus, all equipment's parts under mains voltage are connected to potential equilizer bus through
a green-yellow copper wire of cross-section 2.5 mm2. The bus must be connected to plant pro-
tective earthing network the resistance of which may be maximum 1 Ohm.
On the door of control cabinet, the prescribed high-voltage warning plate is fixed.
The operating devices of machine are connected to 24 V extra-low voltage network.
The proper breakdown voltage isolation is ensured by network transformer and separated ca-
bling. The electric strength of transformer corresponds to a 2.5 kVeff test voltage.
From view-point of shockproofness and humidity tolerance, the units equipment under mains
voltage correspond to protection IP 54 (IEC 529).

SAFETY PRESCRIPTION - OPERATION, MAINTENANCE, REPAIR

CRIMPING MACHINE IS EXPLOITED FROM 230/400 VAC NETWORK, THERE-

FORE, IT IS STRICTLY PROHIBITED TO OPEN THE DOOR OF CONTROL CABI-
NET DURING OPERATION, TOUCH THE PARTS BEING UNDER VOLTAGE!

PROPERLY QUALIFIED AND INSTRUCTED PERSON ONLY IS ALLOWED TO

CARRY OUT MAINTENANCE AND REPAIR!

MAINTENANCE AND REPAIR CAN BE CARRIED OUT IN SWITCHED OF STATE

OF UNIPRÉS ONLY!

TROUBLE SHOOTING ON OPERATING MACHINE CAN BE CARRIED OUT BY PER-

SON INSTRUCTED AND HAVING PASSED SAFETY ENGINEERING

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HEAVY DUTY CRIMPING MACHINE MANUAL

6. MŰSZER ÉS ANYAGJEGYZÉK

Ssz. Megnevezés Tipus/ Gyártó db szám

01. Présasztal vázszerkezet HDPS asztal / Szilágyi 1

02. Nehézüzemi prés H-3-4526 / BMI Kft 1
03. Fényfüggöny 720mm S400S-KSF5N-LH14-ACD7B 1
04. Mérőóra 543 250 B IDC 12/0.001 /MITUTOYO 1
05. Mérőóra tok /D&F 1
06. Mérőóra illesztő egység UI902 /UNIMATIKA 1
07. Mérőóra kábel 2m 905409 /MITUTOYO 1
08. Tuchel összekötő kábel 5p-5p /ker. ag. 1
09. Munkahelyi lámpa NPLL-01 /UNIMATIKA 1
10. Helyzetjelző szerelvény spec /UNIMATIKA 1
11. Biztonsági pozíció kapcsoló 24CE2-S2 /HONEYWELL 1
12. Induktív közelítéskapcsoló PM08-02P /FOTEK 1
13. Nyomástávadó HDA 4445-A-160-000 /HYDAC 1
14. Vezeték leszorító /D&F 1
KEZELŐ ÉS KIJELZŐ ELEMEK
01. Műanyag tokozás XALD02 /SCHNEIDER 1
02. Jelző lámpa zöld XB5-AVB3 /SCHNEIDER 1
03. Jelző lámpa piros XB5-AVB4 /SCHNEIDER 1
04. Nyomógomb zöld XB5-AA31 /SCHNEIDER 3
05. Vészgomb Ø30mm XB5-AS542 /SCHNEIDER 1
06. Tokozat tartólemez 1
07. Hengeres billenőkapcsoló 1

MKR MUNKAHELYI RENDEZŐ DOBOZ

01. Szerelő doboz 190x140x140 mm GW44437 /GEWIS 1
02. Műa.tömszelence + anya V-TEC11 /OBO 1
03. Műa.tömszelence + anya V-TEC16 /OBO 2
04. Fényfüggöny elektronika SafeCIS3-2P-4IO 1
05. Biztonsági relémodul SafeCIS3-EXT-2P 1
06. Biztonsági jelfogó G7SA-2A2B/OMRON 1
07. Jelfogó foglalat P7SA-10F-ND/OMRON 1
08. Jelfogó 40.51 /FINDER 3
09. Jelfogó foglalat 95.05 /FINDER 3
10. Védő diódamodul 6-220VDC 99.01 3000 /FINDER 1
11. Biztositó sork. STK 2PA 1078.2 /CONTA-C 3
12. Zárólemez AP/STK 2/35PA /CONTA-C 1
13. Végbak ES35 2005.2 /CONTA-C 1
14. Áthidaló elem AQ3 2068.0 /CONTA-C 2
15. G05X20 1A F /ker.ag. 1
16. Sorkapocs RKD 2.5-PA/CONTA-CLIP 9
17. Záró lemez AP/RKD 2.5-4PA 1

HIDRAULIKUS EGYSÉGEK

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HEAVY DUTY CRIMPING MACHINE MANUAL

01. Hidraulikus tápegység/S H-3-1415 / BMI Kft 1

02. Hidraulikus váltószelep WEDE-42-AN-10-V-24VDC 1
03. Szeleptömb H-2-2328 Barabás 1
04. Hidraulika olaj 50kg MOL Hidro HM32 1
05. Hidr. gyorscsatakozó anya NS14GASF + GE 12-LR 1
06. Hidr. gyorscsatakozó anya NS38GASF + GE 12-LR 1
07. Hidr. gyorscsatakozó apa NS14GASM + GE 12-LR 1
08. Hidr. gyorscsatakozó apa NS38GASM + GE 12-LR 1
09. Ø10 hidraulikus tömlő 1300mm M18x1,5 E-E csatlakozóval 2

PNEUMATIKUS EGYSÉGEK
01. Levegőelőkészítő FRC-1/8-D-MINI /FESTO 1
02. Elzáró szelep HE-3-1/8-1/8 /FESTO 1
03. Csavarzat ACK 1/8-PK-4 /FESTO 1
04. Pneumatika csatlakozó QR1-S-RPN-G018-DA06 2
05. Pneumatika csatlakozó QR1-S-RVT-G018-DA08 1
06. 4/2-pneumatika szelep V840-4/2OC-DI04 /MECMAN 2
07. El. csatlakozó kupak 894-101-220-2 /MECMAN 2
08. Kezdőlap 898-500-370-2 /MECMAN 1
09. Véglap 898-500-372-2 /MECMAN 1
10. Hangtompító 352-400-202-0 /MECMAN 1
11. Tömítőgyűrü RPD13 /MECMAN 8
12. Dugaszolhatő könyök 979-P-1/4 8
13. Gyorscsatlakozó anya 551M-1/4 12
14. Gyorscsatlakozó apa 515M-1/4 12
15. Pneucső PUN 6/4 /FESTO 5
16. Munkahenger vez.leszorítóhoz, D=25 H=10 0822-010-631/Rexroth 1
UPVE/17 VEZÉRLŐSZEKRÉNY
01. 500x500x250 CRN55/250 /HIMEL 1
02. Fém szerelőlap MM55 /HIMEL 1
03. Főkapcsoló GK20A T203/04E /GANZ KK 1
04. Motorvédő kapcsoló3X230V 10A 24VDC GZ1-M14K1-BD /TELEMECH 1
05. Segéd érintkező LA1-KN31 /TELEMECH. 1
06. Pillanat érintkező 3Z+1NY / TELEMEC. 1
07. Megfogó dióda LA4KC1B / TELEMEC. 1
08. Kismegszakitó 1P+N 10A DPNa „C” 19144 /MERLIN-GERIN 1
09. Kismegszakitó 3P-20A C 23881 /MERLIN-GERIN 1
10. Nyomógomb fekete XB5-AA21 /SCHNEIDER 1
11. Nyomógomb zöld I XB5-AA331 /SCHNEIDER 1
12. Nyomógomb piros 0 XB5-AA432 /SCHNEIDER 1
13. Jelző lámpa zöld XB5-AVB3 /SCHNEIDER 2
14. Jelző lámpa piros XB5-AVB4 /SCHNEIDER 1
15. Hálózati tápegység HA 9502 230VAC/24VDC-5A 1
16. Zavar szűrő 230VAC / 2A Z4302 /REMIX 1
17. PLC progr. vez. PS4-141-MM1 /K&M 1
18. Örzőelem ZB4-600-BT1 /K&M 1
19. PLC kimeneti bővítőegység UE107 /UNIMATIKA 1

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HEAVY DUTY CRIMPING MACHINE MANUAL

20. Távadó illesztő UI901 /UNIMATIKA 1

21. Szelepvezérlő UI904 /UNIMATIKA 1
22. Teljesítmény kapcsoló UI401 /UNIMATIKA 1
23. Lámpateszt modul UE101 /UNIMATIKA 1
24. Jelfogó 55.34 /FINDER 1
25. Megfogó dióda 99.01 3000 /FINDER 1
26. Jelfogó foglalat 94.74 /FINDER 1
27. Biztositó sork. STK 2PA 1078.2 /CONTA-C 4
28. Zárólemez AP/STK 2/35PA /CONTA-C 1
29. Végbak ES35 2005.2 /CONTA-C 8
30. Áthidaló elem AQ3 2068.0 /CONTA-C 2
31. Biztosítóbetét G05X20 3A F /ker.ag. 4
32. Csatlakozó elem RK 6-10PA 1005.2 /CONTA-C 8
33. Földelőtömb SL6 1
34. Záró lemez AP2.5-10PA 2001.2 /CONTA-C 1
35. Választó lemez TW2.5-10PA 2002.2 /CONTA-C 5
36. Kereszt kötés Q2 2060.0 /CONTA-C 2
37. Csatlakozó elem RK 2.5-PA 1030.2 /CONTA-C 4
38. Záró lemez AP 1.5-4PA 2070.2 /CONTA-C 1
39. Csatlakozó elem RKD 2.5-PA STK 2PA 1206.2 /CONTA-C 12
40. Záró lemez AP/RKD 2.5-4PA AP/STK 2/35PA /CONTA-C 1
41. Jelölő matricák no 1...10, 31…50, 10 üres SB 6/10FW /CONTA-CLIP 4
42. Műa.tömszelence + anya V-TEC9 /OBO 2
43. Műa.tömszelence + anya V-TEC11 /OBO 3
44. Műa.tömszelence + anya V-TEC13,5 /OBO 1
45. Műa.tömszelence + anya V-TEC16 /OBO 4
46. Tömszelence osztó DIX 16260 /LAPPKÁBEL 4
47. Hordozó sin TS 35/7,5 /CONTA-CLIP 2m
48. Perf. vezeték csatorna Vk 30x30 /OBO 2m
49. Földelőbak 2
50. Földelősín 10 x 3 0,5m
51. Földelőbilincs ZB4 11

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