1208351

User manual UM EN CF 500 Electric crimper CF 500 User manual Electric crimper CF 500 2012-04-10 Designation: UM EN CF 500 Revision: 03 Order No.: — This user manual is valid for: Designation Order No. CF 500-230V 1208348 CF 500-120V 1208351 102576_en_03 PHOENIX CONTACT Please observe the following notes 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 result 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 PHOENIX CONTACT 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. PHOENIX CONTACT CF 500... Table of contents 1 2 3 4 5 A i Basic information ....................................................................................................................1-1 1.1 Intended use....................................................................................................... 1-1 1.2 Workplaces ........................................................................................................ 1-2 1.3 For your safety.................................................................................................... 1-2 Description of the CF 500 .......................................................................................................2-1 2.1 Supplied as standard.......................................................................................... 2-1 2.2 Overview of the operating components .............................................................. 2-1 2.3 Function of the operating components...............................................................2-2 2.4 Scope of use of the CF 500 ................................................................................2-2 Starting up the CF 500 ............................................................................................................3-1 3.1 Overview ............................................................................................................3-1 3.2 How to proceed .................................................................................................. 3-1 Operation ................................................................................................................................4-1 4.1 One-step crimping ..............................................................................................4-1 4.2 Two-step crimping ..............................................................................................4-2 Troubleshooting ......................................................................................................................5-1 5.1 "Error" LED lights up ...........................................................................................5-1 5.2 CF 500 will not switch on .................................................................................... 5-2 Appendix ................................................................................................................................ A-1 PHOENIX CONTACT A1 Ordering data .................................................................................................... A-1 A2 Technical data ................................................................................................... A-3 A3 Declaration of conformity................................................................................... A-4 102576_en_03 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 A-1). 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. WARNING: All persons responsible for startup, operation, and maintenance of the CF 500 must be appropriately qualified and adhere strictly to this user manual. The CF 500 is used for crimping various types of crimp contacts: – Ferrules – TWIN ferrules – Turned contacts – Slip-on sleeves and flat plugs – Insulated cable lugs – Cable lugs – Tube lugs Other crimp contacts on request. Permitted operators Only authorized and instructed operators may work with the CF 500. The operator is responsible for all other persons within the workspace. The owner must make the user manual available to the operator and ensure that the operator has read and understood it. WARNING: Only use original crimp dies and replacement parts from Phoenix Contact. 102576_en_03 PHOENIX CONTACT 1-1 English Basic information 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 (operating 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 circumstances must it be modified, removed or bypassed by means of alterations. WARNING: The CF 500 must only be operated with the protective cover attached. Disconnect the mains plug prior to all work that requires removal of the protective cover (e.g., crimping die adjustment). Switch off the electric crimper during breaks and when the device is not being used. For reasons of safety, the CF 500 automatically switches off when the protective cover is removed. WARNING: Disconnect the mains plug before opening the housing. 1-2 PHOENIX CONTACT 102576_en_03 2 Description of the CF 500 2.1 Supplied as standard 1 2 3 4 Basic device CF 500 Protective cover Power cable Foot pedal User manual 2.2 Overview of the operating components 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 approximately 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. 102576_en_03 PHOENIX CONTACT 2-1 English Description of the CF 500 CF 500... 2.3 Function of the operating components "Ready" LED – indicates that the unit is ready for operation. "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. "Reset" button – resets the counter reading to zero. "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. "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. "Enter" button – clears the "Error" LED. "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. 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. 2.4 Scope of use of the CF 500 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 inserted 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 2-2 PHOENIX CONTACT Available crimping dies are listed in the "Crimping dies and protective covers" ordering data on page A-1. A protective cover with a suitable insertion slot is assigned to each crimping die. 102576_en_03 3 Starting up the CF 500 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 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). Removing the protective cover WARNING: Risk of injury Disconnect the mains plug before removing the protective cover. • • 102576_en_03 Unscrew the screw (1). Remove the protective cover (2). PHOENIX CONTACT 3-1 English Starting up the CF 500 CF 500... Fitting the crimping die NOTE: Observe the mounting position: – Small cross section to the front – Large cross section to the rear • • • • 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. 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. Connecting and switching on the CF 500 • Connect the foot pedal (1) to the foot pedal connection. 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). • • 3-2 PHOENIX CONTACT 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). 102576_en_03 Centering the crimping die NOTE: The crimping die bore holes have some play for the mounting screws. Therefore you need to center and adjust the crimping die. • • • Press the "operating mode 1" and "enter" buttons simultaneously (1). The LEDs for the "operating mode 1 + 2" buttons flash (2). Push the adjusting slide (3) to position 1. 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. • • • Press and hold down the foot pedal (4). The crimping die (5) closes slowly, until it meets with resistance and centers itself. Release the foot pedal (6). Adjusting the crimping die WARNING: Risk of injury Disconnect the mains plug before removing the protective cover. • • • • • • • 102576_en_03 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 necessary (4). Tighten the screws (5). Attach the protective cover (6) and tighten the screw (7). PHOENIX CONTACT 3-3 English Starting up the CF 500 CF 500... 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. NOTE: The device is set to operating mode 2. Check the operating mode before each use. Setting the optimum press capacity start (1 ... 5) 1 • • • • 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 3-3). Insert the wire and the crimp contact. NOTE: Ensure the cross section is correct. • • • • • 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. NOTE: Changes to settings only take effect after the next crimping process. • • • 3-4 PHOENIX CONTACT 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. 102576_en_03 4 Operation 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. NOTE: Ensure the cross section is correct. • • • Press the foot pedal (3) until the crimping die is completely closed (4). The crimping die (5) opens automatically; release the foot pedal (6). Remove the crimp contact with crimped wire (7). NOTE: If there was a fault with the crimping, the "error" LED lights up (see page 5-1). Shutting down • • 102576_en_03 If necessary, read the counter (1). Switch off the CF 500 with the mains switch (2) (press 0). PHOENIX CONTACT 4-1 English Operation CF 500... 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 NOTE: Ensure the cross section is correct. • • • 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 completely closed (3). The crimping die (4) opens automatically; release the foot pedal (5). Remove the crimp contact with crimped wire (6). NOTE: If there was a fault with the crimping, the "error" LED lights up (see page 5-1). Shutting down • • 4-2 PHOENIX CONTACT If necessary, read the counter (1). Switch off the CF 500 with the mains switch (2) (press 0). 102576_en_03 5 Troubleshooting 5.1 "Error" LED lights up 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. Crimping die incorrectly adjusted WARNING: Risk of injury Disconnect the mains plug before removing the protective cover. • • • • • • 102576_en_03 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). PHOENIX CONTACT 5-1 English Troubleshooting CF 500... 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 WARNING: Risk of injury Switch off the CF 500 via the mains switch and disconnect the mains plug. • • • • • • 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 ordering data on page A-1). Insert the fuse holder.. NOTE: The fuse holder must snap into place. 5-2 PHOENIX CONTACT 102576_en_03 English A Appendix A1 Ordering data Electric crimper Description Type Order No. Electric crimper 230 V CF 500-230V 1208348 1208351 Electric crimper 120 V CF 500-120V 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 Order No. 1212238 CF 500/COV AI 6 Order No. 1212254 CF 500/DIE AI 25 Order No. 1212239 CF 500/COV1 Order No. 1212250 For ferrules (A… and AI…), 0.25 ... 6 mm2 CF 500/DIE AI 50 CF 500/COV1 Order No. 1212261 Order No. 1212250 For ferrules (A… and AI…), 10, 16, and 25 mm² CF 500/DIE AI-TWIN 10 CF 500/COV AI-TWIN Order No. 1212262 Order No. 1212266 For ferrules (A… and AI…), 35 and 50 mm² CF 500/DIE TC 4 CF 500/COV1 Order No. 1212237 Order No. 1212250 CF 500/DIE TC 10 Order No. 1212260 For turned contacts (CK...), 0.14 ... 4 mm² CF 500/DIE SC 1,5 CF 500/COV SC Order No. 1212241 Order No. 1212251 For turned contacts (CK…), 6 ... 10 mm² CF 500/DIE SC 6 CF 500/COV SC Order No. 1212242 Order No. 1212251 For slip-on sleeves and flat plugs (SCF..., SCM…), 0.1 ... 1.5 mm² 102576_en_03 For TWIN ferrules (AI-TWIN), 2 x 4, 2 x 6, and 2 x 10 mm² 1 CF 500/COV Order No. 1212250 For slip-on sleeves and flat plugs (SCF…, SCM…), 0.5 ... 6 mm² PHOENIX CONTACT A-1 CF 500... CF 500/DIE RCI 6 Order No. 1212240 CF 500/COV RCI Order No. 1212255 For insulated cable lugs (RCI, FCI,...), 0.5 ... 6 mm² CF 500/DIE RCI 6-1 CF 500/COV RCI Order No. 1212691 Order No. 1212255 CF 500/DIE RCI 1,5 Order No. 1212263 CF 500/COV RCI Order No. 1212255 For insulated cable lugs (RCI, FCI,...), 0.14 ... 1.0 mm² CF 500/DIE SR 6-2 CF 500/COV RCI Order No. 1212692 Order No. 1212255 For insulated cable lugs (C-RCI, C-FCI) 0.5 ... 6 mm², asymFor solar contacts 2.5 ... 6 mm² metrical 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/COV1 Order No. 1212244 Order No. 1212252 Order No. 1212257 Order No. 1212250 For cable lugs according to DIN 46234 (RC, FC,…), 0.5 ... 10 mm² CF 500/DIE RCT 2,5 CF 500/COV RCT 2,5 Order No. 1212243 Order No. 1212253 For cable lugs according to DIN 46234, (RC, FC,…), 16 mm² CF 500/DIE RCT 10-1 Order No. 12122452) CF 500/COV RC 10 Order No. 1212252 ∅ e/i 4 mm² 5/3 6 mm² 6.5/3.8 10 mm² 7/4.5 For tube lugs, 0.34 ... 2.5 mm² CF 500/DIE RCT 10-2 CF 500/COV RC 10 Order No. 12122462) Order No. 1212252 ∅ e/i 4 mm² 5/3 6 mm² 5.5/3.8 10 mm² 6/4.5 For tube lugs according to DIN 46235, 4 ... 10 mm² A-2 For tube lugs (standard), 4 ... 10 mm² CF 500/DIE RCT 10-3 CF 500/COV1 Order No. 12122562) Order No. 1212250 ∅ e/i 4 mm² 5/3 6 mm² 6/4 10 mm² 8/5 For tube lugs (special), 4 ... 10 mm² 1) CF 500 - Protective cover without recess 2) ∅ e/i (external/internal diameter, in millimeters), in relation to the cross section of the cable lug PHOENIX CONTACT 102576_en_03 English 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. Type Order No. Crimp contacts Die Protective cover CF 500/LOC SCF 6,3/6 1212247 Slip-on sleeves (SCF…) up to 6.3 mm wide CF 500/DIE SC 6 CF 500/COV SC CF 500/LOC SCF 4,8/2,5 1212248 Slip-on sleeves (SCF…) up to 4.8 mm wide CF 500/DIE SC 1,5 CF 500/COV SC Slip-on sleeves (SCF…) up to 2.8 mm wide and 5 mm long CF 500/DIE SC 1,5 Flat plug (SCM...), 0.5 ... 2.5 mm² CF 500/DIE SC 1,5 Flat plug (SCM...), 1.5 ... 6 mm² CF 500/DIE SC 1,5 CF 500/LOC SCF 2,8/1,5 CF 500/LOC SCM 6,3/2,5 CF 500/LOC SCM 6,3/6 1212249 1212264 1212265 CF 500/DIE SC 6 CF 500/COV SC CF 500/DIE SC 6 CF 500/COV SC CF 500/DIE SC 6 CF 500/COV SC CF 500/DIE SC 6 A2 Technical data Technical data Mains connection CF 500-230V 230 V/50 Hz CF 500-120V 120 V/60 Hz Power consumption 160 VA Maximum press capacity 10 kN Press time