TRASLATION OF ORIGINAL INSTRUCTIONS

CRIMP DATA ANALYZER

CDA10

USE AND MAINTENANCE MANUAL

Model: CDA10 Customer:

Serial number: Year of manufacturer: 2019

Revision: 01
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REVISION
REVISION
MODEL LINGUA DATE REVISION NOTES
CDA10 English 10/08/2019 00 Release
CDA10 English 10/01/2020 01 Update

The information contained in this manual is the property of Mecal S.r.l.

The drawings and other documents accompanying the machine are the property of Mecal S.r.l.

Distributing and/or duplicating this manual in any form, whole or partially, without written
authorisation from Mecal S.r.l. is prohibited.

Mecal S.r.l. reserves the right to modify the characteristics of the product described in this manual
without notice.

In case of doubts or difficulties in understanding or interpreting this manual, the original/official

version indicated as "ORIGINAL INSTRUCTIONS" on the cover must be considered as the valid
version.

All of the images included in this manual should be considered as examples only, as they may not
refer to the machine described here.

The Crimp Data Analyser – CDA10 addressed by this manual will hereinafter
be referred to as "interchangeable equipment" or "equipment".

The Crimp Data Analyser – CDA10 is an interchangeable device which,

assembled with a main system called "machine," adds a new function to the
latter.

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STRUCTURE OF THE MANUAL

The manual is divided into 9 chapters, the last of are the attachments.

CHAPTER 1 - GENERAL INFORMATION

This chapter contains general descriptions regarding the structure of the manual.

CHAPTER 2 - SAFETY

This chapter contains a description of the standards, the environmental operating conditions,
ergonomics, the accident prevention devices used, the residual risks and the monitoring plates
applied to the machine.

CHAPTER 3 - GENERAL DESCRIPTION

This chapter contains a description of the operating principles of the machine, the work cycle, the
general technical data and the description of the mechanical, electrical and fluidic units making up
the machine itself.

CHAPTER 4 - PACKAGING AND TRANSPORT

This chapter contains instructions for correctly packaging, handling, transport and unloading at the
user facility.

CHAPTER 5 - INSTALLATION

This chapter contains instructions for correctly carrying out installation at the user facility,
connections to the facility's power supplies, verifications, checks and any adjustments to be carried
out before start-up.

CHAPTER 6 - USE

This chapter, intended for operators and maintenance personnel, contains instructions for starting
and using the machine in its various operating cycles, with descriptions of the controls available to
the operator, the most important operating sequences and use of the diagnostic systems.

CHAPTER 7 - DISMANTLING

This chapter contains warnings and instructions for correctly performing decommissioning and
dismantling of the machine at the end of its operational life.

CHAPTER 8 - MAINTENANCE

This chapter, intended for maintenance technicians, contains the machine maintenance plan. It
provides warnings, precautions and instructions for properly performing maintenance operations
on the machine.

CHAPTER 9 - ATTACHED DOCUMENTATION

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CONTENTS
1. GENERAL INFORMATION..................................................................................................................... 10
1.1 INTRODUCTION ......................................................................................................................................... 10
1.2 SUPPORT ................................................................................................................................................... 10

1.3 GLOSSARY .................................................................................................................................................. 11

1.4 SIMBOLS .................................................................................................................................................... 13

1.5 MANUFACTURER’S INFORMATION ........................................................................................................... 14

1.6 SAFETY STANDARDS .................................................................................................................................. 15

1.7 MANUFACTURER’S RESPONSIBILITIES ...................................................................................................... 15

1.8 MACHINE MANAGEMENT ......................................................................................................................... 16

1.9 CONDITIONS CHECK .................................................................................................................................. 16

1.10 WARRANTY .............................................................................................................................................. 17

2. SAFETY ............................................................................................................................................................ 21
2.1 GENERAL INFORMATION........................................................................................................................... 21
2.1.1 Machine certification ......................................................................................................................... 22
2.1.2 Intended and improper uses.............................................................................................................. 23
2.2 ENVIRONMENTAL OPERATING CONDITIONS ............................................................................................ 24
2.2.1 Fire protection installation................................................................................................................. 24
2.2.2 Explosive atmosphere ........................................................................................................................ 24
2.2.3 Lighting............................................................................................................................................... 24
2.2.4 Ergonomics......................................................................................................................................... 24
2.2.5 Vibrations ........................................................................................................................................... 25
2.2.6 Noise .................................................................................................................................................. 25
2.2.7 Electromagnetic emissions ................................................................................................................ 25
2.3 DISPOSAL OF EXHAUSTED MATERIALS...................................................................................................... 26
2.4 DANGER ZONES ......................................................................................................................................... 26
2.5 SAFETY DEVICES APPLIED TO THE MACHINE ............................................................................................ 26
2.6 RESIDUAL RISKS ......................................................................................................................................... 27
2.6.1 General information........................................................................................................................... 27
2.6.2 Residual risks ...................................................................................................................................... 27
2.6.3 Plates present on the machine .......................................................................................................... 28

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3. GENERAL DESCRIPTION .................................................................................................................................. 32

3.1 LAYOUT...................................................................................................................................................... 32
3.2 TECHNICAL INFOMATION.......................................................................................................................... 35
3.3 DESCRIPTION OF UNITS ............................................................................................................................. 36
3.3.1 Adjustable support............................................................................................................................. 36
3.3.2 Control unit ........................................................................................................................................ 36
3.3.3 Force cell sensor ................................................................................................................................ 37
3.3.4 Encoder .............................................................................................................................................. 38
4. PACKAGING AND TRASPORT.......................................................................................................................... 42
4.1 PACKAGING ............................................................................................................................................... 42
4.2 TRASPORT.................................................................................................................................................. 43
4.3 LIFTING AND HANDLING ........................................................................................................................... 44
4.3.1 Weight of packages ........................................................................................................................... 45
5. INSTALLATION ................................................................................................................................................ 49
5.1 MACHINE INSTALLATION .......................................................................................................................... 49
5.1.1 General safety precautions ................................................................................................................ 49
5.1.2 Choosing the site and verifying installation requirements ................................................................ 50
5.1.3 Positioning and assembling the equipment ...................................................................................... 50
5.1.4 Positioning and assembling the force cell sensor on TT and P107 presses ....................................... 51
5.1.5 Positioning and assembling the force cell sensor on P040 and P080 presses ................................... 52
5.1.6 Positioning and assembling the encoder ........................................................................................... 53
5.2 CONNECTIONS........................................................................................................................................... 54
5.2.1 Connecting to electrical mains on TT and P107 presses .................................................................... 54
5.2.2 Connecting to electrical mains on P040 presses................................................................................ 55
5.2.3 Connecting to electrical mains on P080 and P120 presses ............................................................... 56
5.2.4 Replacing the force cell TT1000 with CDA10 ..................................................................................... 57
5.2.5 Auxiliary connecting ........................................................................................................................... 58
5.3 CHECKS AND VERIFICATIONS .................................................................................................................... 59
5.3.1 General checks on the mechanical units ........................................................................................... 59
5.3.2 Electrical system check ...................................................................................................................... 60
5.4 UNIVERSAL INTERNATIONAL RECYCLING CODES ...................................................................................... 61
6. USE .................................................................................................................................................................. 67
6.1 SWITCH ...................................................................................................................................................... 67
6.2 ELECTRICAL CIRCUIT .................................................................................................................................. 67

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6.3 CONTROL AND SENSOR SYSTEMS ............................................................................................................. 68

6.4 MACHINE ARRANGEMENT ........................................................................................................................ 69
6.4.1 Encoder configuration........................................................................................................................ 69
6.4.2 Acoustic signal setting........................................................................................................................ 70
6.4.3 Web connection ................................................................................................................................. 71
6.4.4 Network setting ................................................................................................................................. 73
6.4.5 Software update ................................................................................................................................ 74
6.4.6 Sensor calibration .............................................................................................................................. 76
6.4.7 Crimp force detection history ............................................................................................................ 77
6.4.8 Operating password setting ............................................................................................................... 79
6.5 MACHINE USE PROCEDURES ..................................................................................................................... 80
6.5.1 Initial checks....................................................................................................................................... 80
6.5.2 Connecting power .............................................................................................................................. 80
6.5.3 Operating mode ................................................................................................................................. 80
6.5.4 Switching off the machine ................................................................................................................. 80
6.6 USE ............................................................................................................................................................ 81
6.6.1 Learning.............................................................................................................................................. 81
6.6.2 Production.......................................................................................................................................... 83
6.6.3 How crimp force curve mismatch is calculated ................................................................................. 84
6.6.4 Crimp fail ............................................................................................................................................ 86
6.6.5 Parameters setting (Analysis Menu) .................................................................................................. 87
6.6.6 Error messages ................................................................................................................................... 88
6.7 UNLOADING THE MACHINE ...................................................................................................................... 90
6.7.1 Reel unloading procedure .................................................................................................................. 90
6.8 FAULTS....................................................................................................................................................... 91
7. DISMANTLING................................................................................................................................................. 94
7.1 DISPOSAL ................................................................................................................................................... 95
8. MAINTENANCE ............................................................................................................................................... 99
8.1 GENERAL SAFETY PRECAUTIONS ............................................................................................................... 99
8.1.1 General hazard notes ....................................................................................................................... 100
8.1.2 General warnings ............................................................................................................................. 101
8.2 QUALIFICATION OF MAINTENANCE PERSONNEL .................................................................................... 103
8.2.1 General skills .................................................................................................................................... 103
8.2.2 Skills related to qualified personnel................................................................................................. 103

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8.3 SAFETY CONTROL PLAN........................................................................................................................... 107

8.3.1 Functional checks and tests on safety devices ................................................................................ 107
8.4 MACHINE STOP PROCEDURE .................................................................................................................. 108
8.5 MAINTENANCE SHEETS ........................................................................................................................... 109
8.6 SPARE PARTS ........................................................................................................................................... 111
8.6.1 Mechanical spare parts .................................................................................................................... 111
8.6.2 Electrical spare parts ........................................................................................................................ 111
9. ATTACHED DOCUMENTATION ..................................................................................................................... 115
9.1 LAYOUT.................................................................................................................................................... 116

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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1. GENERAL INFORMATION
1.1 INTRODUCTION

Mecal S.r.l., manufacturer of the equipment in question, will hereafter be

referred to as “Manufacturer”.

The company that purchased the equipment will hereinafter be referred to as

"Client".

This manual contains all the information necessary for correct installation, regular use and suitable
maintenance of the machine.

The Manufacturer requires that personnel in charge of running and maintaining the machine,
as well as personnel in charge of transport and assembly operations, read this document.

This document is the use and maintenance manual for the machine:

CRIMP DATA ANALYZER - CDA10

and has been compiled in compliance with Machinery Directive 2006/42/CE.

The Use and Maintenance manual is to be considered an integral part of the machine and must be
kept until its final disposal. It must be kept by the person in charge of the machine after final
installation.

1.2 SUPPORT
For technical support, contact:

MECAL S.r.l.

Registered and production office: Strada per Felizzano, 18 - 15043 Fubine (AL) - Italy

Tel. +39 (0)131 792792 - Fax (0)131 792733 / 792734 Fully paid share cap. € 500.000

Register of Alessandria Companies n. 11690 - CCIAA Alessandria - REA N. 153887 - N. IEC AL002563

Tax Code 01328270069 – ISO Code: IT – VAT n.01328270069

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1.3 GLOSSARY
Component: constitutive part of the electrical equipment, usually specified by its function, but
used in various applications.
Contact: person responsible for conducting certain operations or assessments that may occur
during work or maintenance.
Control circuit (of a machine): circuit used to control the operation of the machine and for
protecting power circuits.
Control device: device inserted in a control circuit used for use of the machine.
Danger zone: area inside or near the machine where the presence of an exposed person
constitutes a risk to his/her health and/or his/her safety.
Emergency situation: dangerous situation that needs to be urgently interrupted or avoided.
Emergency stop – emergency stop function: function that is provided:
- To avert arising or reduce existing hazard to person, damage to machinery or to work in progress
and
- To be initiated by a single human action
Exposed person: any person who has their body or any part of their body in a danger zone.
Failure: failure: the end of an element's ability to execute a required function.
Fixed guard: guard affixed in such a manner (for example by screws, nuts and welding) that it can
only be opened or removed by the use of tools or by destruction of the means to which the guard
is affixed.
Guard: physical barrier, designed as part of the machine (for example: using screws, nuts, welds),
to provide protection.
Hazard: potential source of harm.
Improper use: use of the machine outside the limits specified in the technical documentation.
Information for use: Protective measure consisting of communication links (for example, text,
words, signs, signals, symbols, diagrams) used separately or in combination, to convey information
to the user.
Intended use: the use of machinery in accordance with the information provided in the
instructions for use.
Machine: set of pieces or components, of which at least one is mobile, connected to each other,
and possibly with actuators, with control and power circuits, etc., connected for a well-defined
application, particularly for the transformation, treatment, displacement and conditioning of a
material. Interchangeable equipment modifying the function of a machine, which is placed on the
market for the purpose of being assembled with a machine or a series of different machines or
with a tractor by the operator himself in so far as this equipment is not a spare part or a tool.
Machinery Directive: DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL on the approximation of the laws of the Member States relating to machinery.
Malfunction: inability of a machine to perform its intended function.
Marking: symbol and writings for identification of the machine, affixed by the Manufacturer.
Movable guard: guard that can be opened without the use of tools.
Operator: person qualified to install, operate, adjust, clean and maintain the machine.
PLC: Programmable Logic Control able to manage and control all machine movements. Equipped
with electronic boards to control the various devices and to receive the relative control signals.
protection of persons from a present or latent hazard.
Protections (protection criteria): means of protection that uses measures to protect persons
against hazards that cannot be rationally eliminated, against risks that cannot be sufficiently
reduced by protection measures integrated in the design..
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Protective device: means of protection other than a guard.

Protective means: guard or protection device.
Qualified personnel or qualified maintenance personnel: those persons who have attended
specialisation courses, training, etc. and have experience in the installation, commissioning and
maintenance, repair, transport and handling of the machine.
Residual risk: risk that remains after taking protective measures.
Risk: combination of probability of occurrence of harm and the severity of that harm.
Safe operating procedure: a work method that reduces risks.
Safety measure: means that eliminates or reduces a hazard.
Safety protections: guard or protective device used as a safety measure for the
Supplier: Supplier: entity (Manufacturer, installer, systems integrator) that supplies the equipment
or services associated with the machine (the user can also act as a Manufacturer for himself).
Transport: set of operations to transfer the machine from the manufacturer's assembly site to the
Client's final work site.
User: entity that uses the machine and associated electrical equipment.
Work Area: volume delimited by accident prevention guards and intended for machine operation.

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1.4 SYMBOLS
The manual uses some symbols that are intended to draw the attention of the reader and
highlight some particularly important aspects.

SYMBOL MEANING NOTE

Indicates a hazard with risk of injury or even

death for the user.
HAZARD
Pay close attention to text blocks
indicated by this symbol.

Represents a warning of possible

deterioration or damage to the machine and/or
CAUTION equipment.
Pay attention to the text blocks indicated by
this symbol.

Indicates a warning or a note of key

features or of useful information.
WARNING NOTE
Pay attention to the text blocks indicated by
this symbol.

Text blocks that contain complementary

information are introduced by this symbol.
This information has no direct relation to the
ADDITIONAL description of a function or the development of a
INFORMATION procedure. It may be references to other
complementary documentation, such as instruction
manuals for the use of attachments, technical
documents or other sections of this manual.

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1.5 MANUFACTURER CONTACTS

The Manufacturer's Technical Department is always available to Clients for any type of information
or clarification concerning use, maintenance, installation, etc.

The latter should always put the questions in clear terms, with references to this manual, always
indicating the data shown on the identification plate of the machine in question.

Any requests for support at the Customer’s site, or for clarification regarding the technical aspects
of this document, must be addressed to:

Mecal S.r.l.
Registered office and plant: Strada per Felizzano, 18 - 15043 Fubine (AL)
Tel. (0131) 792792 - Fax (0131) 792733/792734 Fully paid share cap. € 500.000
Register of Alessandria Companies n. 11690 - CCIAA Alessandria - REA N.
153887 - N. IEC AL002563
Tax Code 01328270069 – ISO Code: IT - VAT: 01328270069

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1.6 SAFETY STANDARDS

The requirements, indications, standards and related safety notes described in the various chapters
of the manual are intended to define a series of behaviours and obligations which must be followed
when performing the various activities that constitute the intended use of the machine, aimed at
operations that are safe for personnel, equipment and the surrounding environment.

The safety standards listed are intended for all authorised personnel, instructed and delegated to
perform the various activities and operations of:

• Transport
• Installation
• Operation
• Use
• Management
• Maintenance
• Cleaning
• Decommissioning and dismantling

1.7 MANUFACTURER’S RESPONSIBILITIES

The Manufacturer declines all responsibility deriving from incorrect or improper use of the machine
in question and from any damage caused by the use of non-prescribed spare parts, from
maintenance operations not carried out correctly or from tampering with circuits, components and
system software.

The responsibility concerning the application of safety requirements, reported as follows, is at the
expense of the technical personnel responsible for activities foreseen on the machine. Technical
personnel must ensure that the operators authorised to carry out the required activities are
qualified, that they comply with and are aware of the provisions contained in this document and of
the general safety standards applied to the machine.

Failure to comply with safety standards may result in injury to personnel and damage to equipment.

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1.8 MACHINE MANAGEMENT

Machine management is only allowed to be performed by authorised and appropriately trained
operators, or operators with at least sufficient technical experience.

Operators in charge of machine use and maintenance must be aware that the knowledge and
application of safety regulations is an integral part of their work.

Operators not authorised to work on the machine must not have access to their control panels.

Perform the following operations before starting the machine:

• Read this manual carefully;

• Be familiar with which protections and emergency stop devices are present on the machine,
where they are located and how they work;

Removing or even partially removing the protections, safety devices or monitoring plates affixed on
the machine is prohibited. In the event of malfunction or failure of these devices, immediately
repair or replace them.

1.9 CONDITIONS CHECK

Check that machine has not been damaged during transport. Please therefore report any accidents
or presence of visible damage (signs or traces of impact) as follows:

• With a written note on the Transport Document.

• Communicating the damage detected by registered letter to the carrier and to Mecal S.r.l.,
within 48 hours of receipt of the machine.

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1.10 WARRANTY
Mecal S.r.l. guarantees that its machines are free from manufacturing defects for the period of time
indicated in the stipulated contractual conditions.

The purchaser is only entitled to the replacement of parts recognised as defective: the costs of
packaging and transport, as well as any installation, are at the purchaser’s expense. In this case, the
following must be specified:

• Date and number of the purchase document.

• Machine model.
• Serial number.

No claims for damages for production losses caused by any periods of machine downtime will be
recognised.

The warranty does not cover damages due to use that does not comply with the contents of this
"Use and Maintenance Manual," which is an integral part of the machine, including any
maintenance that does not comply with the instructions provided.

La garanzia non sarà riconosciuta per la macchina sulla quale sono state eseguite modifiche non
autorizzate.

The warranty will not be recognised if any unauthorised modifications have been made to the
machine.

Modifications to or tampering with safety devices are strictly prohibited.

In the event of breakages during the warranty period, original spare parts must be used for the
warranty to be valid.

Repair work must only be carried out by specialised operators who are familiar with the machine.

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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2. SAFETY
2.1 GENERAL INFORMATION
The Customer must instruct personnel regarding the risks of injury, the safety devices installed on
the machine and the general accident prevention rules provided for by European Community
directives and by legislation in the country where the machine is installed.

Operators must be familiar with the position and operation of all machine controls and their
characteristics.

Tampering with or unauthorised replacement of one or more machine components and the use of
accessories or spare parts other than those recommended can cause a risk of injury.

HAZARD

Excluding/tampering with the safety devices on the machine is strictly

prohibited. The manufacturer declines all responsibility for the safety of
the machine in the event of non-compliance with this prohibition.

CAUTION

It is the responsibility of the operator using the machine to ensure that the
area is safe and free of people or objects.

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2.1.1 MACHINE CERTIFICATION

The machine is supplied with an EC Declaration of Conformity with the essential safety
requirements in accordance with Machinery Directive 2006/42/EC (Annex II A) and Electromagnetic
Compatibility Directive 2014/30/EU.

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2.1.2 INTENDED AND IMPROPER USES

The CDA10, combined with the press, has been designed and built to compare the force curves of
crimping with reference curves and to check the quality of the work.

Operating specifications:

Range 0 – 20 kN
Temprerature 0 – 70 °C

The machine cannot be used for any use other than that envisaged .

HAZARD

Use of the machine for purposes not described in this manual is considered
IMPROPER USE. The Manufacturer declines all responsibility for any
damage caused to property and/or persons and deems all forms and types of
machine warranty to be forfeited. The Manufacturer declines all
responsibility in the event of tampering with the machine, for unauthorised
modifications and for maintenance operations performed by untrained
personnel.

HAZARD

In the event of abnormal behaviour of the machine or lack of power supply,

carrying out any type of movement is prohibited, as that is under the specific
competence of the operators in charge of maintenance.

CAUTION

Use of the machine by inadequately qualified and instructed personnel is

prohibited. The machine user must have read and understood this
document.

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2.2 ENVIRONMENTAL OPERATING CONDITIONS

The area where the machine is located must be a covered environment equipped with all the safety
arrangements deriving from the laws in force in the user country.

2.2.1 FIRE PROTECTION INSTALLATION

The machine is not equipped with its own fire protection system.

2.2.2 EXPLOSIVE ATMOSPHERE

This machine is not designed or built to work in environments with explosive or partially
atmospheric atmosphere.

2.2.3 LIGHTING
The machine is not equipped with its own lighting system.

NOTE

It is the customer's responsibility to install and use the machine in a suitably lit
environment.

For this reason, a lighting value of at least 500 LUX is recommended for
normal uses with medium details and medium contrasts, as per standard UNI-
EN 1837.

2.2.4 ERGONOMICS
The machine must be positioned and adjusted to meet the physical and cognitive ergonomics
criteria, considering:

• Easy human/machine interfacing,

• Preventing a prolonged concentration and rhythm conditioned by the machine,
• Work spaces suitable for loading and unloading the machine reels,
• A possible variability in the physical dimensions and strength of the operator working.

In case of maintenance, the units that make up the machine are sized in such a way as not to create
fatigue or stress to the operator working.

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2.2.5 VIBRATIONS
The equipment does not produce vibrations that are dangerous for the health of personnel working.

CAUTION

Excessive vibrations can only be caused by a mechanical failure, which must

be immediately reported and eliminated.

2.2.6 NOISE
The equipment does not produce noise that are dangerous for the health of personnel working.

NOTE

Measurements of worker noise exposure levels must be carried out by the

customer in accordance with the legislation in force in their own country.

2.2.7 ELECTROMAGNETIC EMISSIONS

The machine contains electronic components subject to the Electromagnetic Compatibility
regulation, conditioned by conducted and radiated emissions.

The emission values comply with the standard thanks to the use of components complying with the
Electromagnetic Compatibility Directive, suitable connections and the installation of filters where
necessary.

The equipment is therefore compliant with the Electromagnetic Compatibility Directive.

CAUTION

Any maintenance on electrical equipment carried out in a non-compliant

manner, or involving the incorrect replacement of components, may
compromise the efficiency of the equipment itself.

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2.3 DISPOSAL OF EXHAUSTED MATERIALS

In its normal operation, the machine does not produce any kind of waste or exhausted material.

There are specific regulations for environmental protection in every country with relation to the
disposal of such materials.

The Customer must be aware of these regulations and operate in such a way as to comply with
them.

In particular, please see chapter 7 regarding the disposal of the materials that make up the
machine.

2.4 DANGER ZONES

The equipment has no danger zones. See the machine use and maintenance manual to
outline the danger zones of the press.

2.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)

Persons working on the machine must use personal protective equipment such as to minimise
possible risks.

HAZARD

The clothing of those working or performing maintenance on the machine

must comply with the essential safety requirements defined by the European
community directives and by the laws in force in the country where the
machine is installed.

HAZARD

During management and maintenance operations, personnel must wear

suitable work clothing so as to prevent accidents from occurring.

To avoid mechanical risks, such as dragging, trapping or other, pull back hair
and do not wear bracelets, watches, rings or necklaces.

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2.6 RESIDUAL RISKS

2.6.1 GENERAL INFORMATION
All the areas and the parts at risk were evaluated during the design phase, and thus all the
precautions necessary to avoid risks to people and damage to machine components have been
taken.

NOTE

Periodically check the functionality of all safety devices.

Do not remove the protections present.

Do not insert foreign objects and/or tools into the work area of the machine.

2.6.2 RESIDUAL RISKS

After carefully considering all the possible risks related to the machine, all the solutions necessary
have been adopted to eliminate the risks and limit the dangers for exposed persons.

CAUTION

It is necessary to periodically check the regular operation of the safety devices

as a precautionary measure for safety purposes.

Making any kind of modification is strictly prohibited, in order not to create

additional dangers and consequent unforeseen risks.

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2.6.3 PLATES PRESENT ON THE MACHINE

The Manufacturer has installed a series of monitoring plates on the equipment, defined in
accordance with European legislation regarding the graphic symbols to be used. The plates in
question are in a clearly visible position on the machine.

Maintenance service must immediately replace any plates which have become illegible due to wear.

CAUTION

Removing the monitoring plates from the machine is strictly prohibited.

The Manufacturer declines all responsibility for the safety of the machine in
the event of non-compliance with this prohibition.

ADDITIONAL INFORMATION

For information concerning the monitoring plates installed on the integrated

machine parts, please see the specific manuals.

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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3. GENERAL DESCRIPTION
The control unit detects and analyses the force profile obtained by crimping. The profile is
compared with a previously learned one and, in the event of defective crimping, the unit emits a
signal to the press that disables the operating mode.

Operating specifications:

Range 0 – 20 kN
Temperature 0 – 70 °C

3.1 LAYOUT
ITEM DESCRIPTION

1 Adjustable support

2 Control unit

3 Force cell sensor

4 Encoder

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Installation on P040 and P080 presses.

Installation on TT and P107 presses.

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3.2 TECHNICAL FEATURES

The following table shows the main technical features of the machine.

GENERAL TECHNICAL FEATURES

Measuring range 0 – 20 kN

Resolution 10 Newtons

Repeatability 0,1 %

Sensor type Piezo-ceramic

Power supply (from the press) 9 – 24 Vdc

Evaluation time < 20 ms

Communication protocol TCPIP / HTTP / UDP

Dimensioni (unità di controllo) 85 x 103 x 35 mm

Protection degree IP40

Operating temperature da 0 a +70 °C

NOTE

The features shown in the previous table may undergo variations; therefore,
please see the attached diagrams for greater precision or verification of the
machine features.

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3.3 DESCRIPTION OF UNITS

3.3.1 ADJUSTABLE SUPPORT
The bracket is fixed to the press frame.
Controller inclination can be regulated
using the knob.

3.3.2 CONTROL UNIT

Equipped with a display to show the
force curve of the crimping and four
front buttons for choosing the settings
and for performing configuration.
The unit disables the press if it detects
failed crimping.

The connection ports are located at the bottom of the

panel.

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3.3.3 FORCE CELL SENSOR

The piezoelectric sensor
converts the force applied by
the press in an electrical
signal which is read and
monitored by the control
unit.

On model TT and P107

presses, the cell sensor (C)
and the spacer plate (B) are
placed between the support
(A), screwed to the press
slide, and the "T"-connector
(E).

The sensor cable (D) is fixed

with clips to the slide and to
the press frame.

On model P040 and P080 presses, the sensor (C) is

placed between the slide and the shank connection.

The sensor cable (D) is fixed with clips to the press

frame.

Only on these press models, an amplifier must be

inserted between the sensor and the control unit.

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3.3.4 ENCODER
The optical and incremental encoder communicates the direction, speed and position of the press
in operation to the control unit.

The control unit does not intervene if the encoder is accidentally disconnected, as it does not detect
machine activity and cannot report a malfunction. To overcome this problem, the control unit
checks the signal from the encoder (trigger) at start-up and periodically thereafter. If the encoder
status is not detected, the controller emits a beep and a message on the display.

The encoder (M) is installed on its own support (G) and the latter is fixed by means of two spacers
(F) to the holes on the gear motor flange. Motion transmission occurs by means of the control
shaft (H).

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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4. PACKAGING AND TRANSPORT

4.1 PACKAGING
The packaging does not protect from external weather events such as rain, snow, hail, etc., even
when the components are packed and transported in wooden crates. For this reason, if packaging
remains exposed to the elements, it is essential that they remain in closed containers until they
are finally stored.

All external parts subject to oxidation (machined surfaces, unpainted parts, etc.) are protected by
a layer of protective antioxidant oil. The fragile parts are protected by plastic material to prevent
damage during lifting and transport.

CAUTION

The load must always be kept in a vertical position.

Any multiple packages, and if indicated on the packaging, must not be

stacked one on top of the other.

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4.2 TRASPORT
Depending on the destination, the machine can be shipped in the following ways:

• BY SEA → the various parts that make up the machine are enclosed in flat bottomed crates and
anchored with tie rods. The crates are lined and have a door for customs checks. They also
contain bags with desiccant salts against moisture and sea salt.
• BY AIR → the various parts that make up the machine are enclosed in flat bottomed crates and
anchored with tie rods. The crates are lined and have a door for customs checks. They also
contain bags with desiccant salts against moisture and other atmospheric agents.
• VIA GROUND→ transport via ground can be divided into two categories:
 LONG DISTANCE TRANSPORT, where the various parts of the machinery are covered with
protective sheets, enclosed in flat bottomed wooden creates and anchored with tie-rods on
the loading surface of the articulated vehicle.

Carefully follow the instructions printed on the outside of the packaging to lift the crates.
Packaging can be recovered for possible re-use; therefore, it is good practice to try to keep
them in a protected place in order to avoid damaging them and making them unreliable. If
they have to be thrown out, it will be the responsibility of the Customer to dispose of them
according to the regulations in force in their own country.

 MEDIUM AND SHORT DISTANCE TRANSPORT, where each individual component of the
machinery is fixed to a platform and covered with protective sheets.

The anchorage points for lifting are indicated on the transport packages.

All the indications for identification of the contents and for safe handling are also provided
on the outside of the various packages:

 Address of recipient and sender.

 Dimensions (length, width, height).
 Gross, net and tare weight.
 Centre of gravity.
 Annotations and pictograms (i.e. fragile, tall, etc.).
 Packing list plate (a copy must be present inside each package).

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4.3 LIFTING AND HANDLING

You must know the weight of the machine before performing any handling and/or lifting..

CAUTION

All handling and/or lifting operations must be carried out by qualified

personnel, aware of the standards regarding the lifting and handling of loads,
and in full compliance with them.

CAUTION

Use a suitable lifting device, adequate for the weight and the encumbrance of
the load to be handled.

CAUTION

Always ensure correct balancing of the load. If it is unbalanced, immediately

place it on the ground and reposition it.

CAUTION

When the load is lifted to a height greater than 50 cm, the operators must
remain at a safe distance from the perimeter, greater than 2m.

A break in the slings or an uncontrolled movement of the load are in fact

serious dangers to personnel safety.

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4.3.1 WEIGHT OF PACKAGES

Description Weight

Complete equipment

 Adjustable support

 Controller

 Force cell sensor

 Encoder

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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5. INSTALLATION
Before installing the equipment:

• Remove the protective packaging of the various parts that make up the equipment;
• Remove any fasteners used for transportation.

5.1 EQUIPMENT INSTALLATION

5.1.1 GENERAL SAFETY PRECAUTIONS
The operations described in this paragraph must be performed by authorised personnel.
Unauthorised personnel must remain outside the installation area.

HAZARD

Make sure there is nothing around during installation of the various parts that
make up the machine (cables, pipes, etc.) that could cause interference or
danger to operators.

CAUTION

Personnel in charge of all installation, connection, checks and verifications

must be trained to avoid incorrect operations that could damage the
machine.

ADDITIONAL INFORMATION

See the specific manuals for information on the integrated devices.

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5.1.2 CHOOSING THE SITE AND VERIFYING INSTALLATION

REQUIREMENTS
The customer MUST prepare:

• A sufficiently large room, free from obstacles, equipped according to the safety regulations in
force in the user country.
• Proper ventilation and lighting.
• Appropriate lifting means.
• Operating spaces.
• Transit routes.
• Escape routes.
• Flooring capable of supporting the weight of the machine.
• A general power supply, including the earthing conductor, according to the characteristics and
tolerances required.

5.1.3 POSITIONING AND ASSEMBLING THE EQUIPMENT

See the attached layout to position the equipment on the machine.
The controller is positioned above the adjustable support, which in turn is fixed to the press frame
with two screws. There are different adapter holes, depending on the type of press on which
the swivel support is fixed.

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5.1.4 POSITIONING AND ASSEMBLING THE FORCE CELL SENSOR ON TT

AND P107 PRESSES
Follow the procedure below to install the load cell on press models TT and P107:
• Fit the T-connector support (A) with the two hex
socket head cap screws (N) on the press slide;
• Insert the load cell sensor (C), interposing the plate (B)
and locking it with the T-connector (E);
• Insert the hex socket head cap screw (P) and tighten it
with a torque wrench, setting a tightening torque of 7
Nm;
• Connect the plug (D) to the sensor.

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5.1.5 POSITIONING AND ASSEMBLING THE FORCE CELL SENSOR ON P040

AND P080 PRESSES
Follow the procedure below to install the load cell on press models P040 and P080:
• Insert the load cell sensor (C) between the press slide and the shank connection (Q);
• Insert the hex socket head cap screw (P) and tighten it with a torque wrench, setting a tightening
torque of 40 Nm;
• Position the collar (R) of the shank connector (Q) and secure it with two hex socket head cap
screws (N).
• Connect the plug (D) to the sensor and to the amplifier.
• Connect the plug to the amplifier and to the control unit.
• Position the amplifier inside the electrical box of the press.

Amplifier for P040 e

P080 presses

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5.1.6 POSITIONING AND ASSEMBLING THE ENCODER

Proceed as follows to install the encoder unit:

• Tighten the headless screw, or grub screw (T), on the encoder control shaft (U);
• Tighten the hub (U) at the end of the output shaft (S) from the gear motor, on the grub screw (T)
that has just been inserted;
• Position the two spacers (V) and washers in the threaded holes on the gear motor flange of the
press and secure them;
• Install the encoder (X) on the encoder support plate (W) using three cylindrical-head screws with
Phillips head;
• Position the hub (U) on the encoder shaft (X), leaving it free;
• Take the support plate unit with the newly assembled encoder and secure it in place by
tightening the two hex socket head cap screws with washers;
• Connect the encoder connector to the sensing unit;
• Install the encoder on the sensing unit at angle 351° ±7° [follow the instructions in relative
paragraph 6.4.1];
• At the same time as the previous installation phase, tighten the headless screw, or grub screw,
on the hub (U).

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5.2 CONNECTIONS
The machine must have the following connections:

• Electrical

HAZARD

Machine power supply connection operations must be carried out solely by

specialised personnel and are subject to use of personal protective
equipment.

5.2.1 CONNECTING TO THE ELECTRICAL MAINS ON TT AND P107 PRESSES

5.2.1.1 STANDARD
The operations to be carried out to connect the load cell electrically are:
• Check that the switch, located on the press or in the electrical cabinet/panel, is in the OFF (O)
position.
• Disconnect the press from the electrical mains.
• Open the electrical box of the press.
• Intercept the cables from the load cell: white, brown, yellow and green.
• Connect the brown cable to the pos.4 input [+18V] on the terminal board (combined with the
cable present).
• Connect the white cable to the pos.5 input on the terminal board (combined with the cable
present).
• Connect the green cable to the pos.12 input on the terminal board (combined with the cable
present).
• Connect the yellow cable to the black cable with PD indication by means of the supplied clamp.
• Close the electrical box with the screws.
• Connect the press to the electrical mains.
• Move the switch to the ON (I) position.
• Configure the load cell [see the relative paragraph].

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5.2.1.2 STANDARD
The operations to be carried out to connect the load cell electrically are:
• Check that the switch, located on the press or in the electrical cabinet/panel, is in the OFF (O)
position.
• Disconnect the press from the electrical mains.
• Open the electrical box of the press.
• Intercept the cables from the load cell and BCC: white, brown, yellow, green, rose and grey.
• Connect the brown cable to the pos.4 input [+18V] on the terminal board (combined with the
cable present).
• Connect the white cable to the pos.5 input on the terminal board (combined with the cable
present).
• Connect the grey cable to the pos.10 input on the terminal board (combined with the cable
present).
• Connect the green cable to the pos.12 input on the terminal board (combined with the cable
present).
• Connect the yellow cable to the black cable with PD indication by means of the supplied clamp.
• Connect the rose cable to the black cable with PX indication by means of the supplied clamp.
• Close the electrical box with the screws.
• Connect the press to the electrical mains.
• Move the switch to the ON (I) position.
• Configure the load cell [see the relative paragraph].

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5.2.2 CONNECTING TO THE ELECTRICAL MAINS ON P040 PRESSES

The operations to be carried out to connect the load cell electrically are:
• Check that the switch, located on the press or in the electrical cabinet/panel, is in the OFF (O)
position;
• Disconnect the press from the electrical mains;
• Open the compartment for
housing the electrical
components of the machine;
• Intercept the cables from the
load cell: white and brown;
• Connect the white cable to
the pos.9 input on the
terminal board [located on
the left side, seen from the
rear, in the electrical box of
the press];
• Connect the brown cable to
the pos.10 input on the
terminal board;

• Intercept the yellow and

green cables (both are
equipped with clamp), coming
from the load cell;
• Connect the yellow cable to
the black cable with PD-
indication by means of the
supplied clamp;

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• Eliminate clamp by the green cable and connect it to the

pos.6 input on the terminal board [located on
the right side, seen from the rear, in the
electrical box of the press];
• Close the electrical box housing
compartment with the screws;
• Connect the press to the electrical mains;
• Move the switch to the ON (I) position;
• Configure the load cell [see the relative
paragraph].

5.2.3 CONNECTING TO THE ELECTRICAL MAINS ON P080 & P120 PRESSES

The operations to be carried out to connect the load cell electrically are:
• Check that the switch, located on the press or in the electrical cabinet/panel, is in the OFF (O)
position;
• Disconnect the press from the electrical mains;
• Open the electrical box of the press;
• Intercept the cables from the load cell: white, brown, yellow and green;
• Connect the white cable to the pos.3 input on the terminal board (combined with the cable
already present);
• Connect the brown cable to the pos.4 input on the terminal board (combined with the cable
present);

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• Connect the yellow cable to the pos.6 input on the terminal board;
• Connect the green cable to the pos.7 input on the terminal board;
• Close the door on the electrical box;
• Connect the press to the electrical mains;
• Move the switch to the ON (I) position;
• Configure the load cell [see the relative paragraph].

5.2.4 REPLACING THE FORCE CELL TT1000 WITH CDA10

The operations to be carried out to replace load cell TT1000 with load cell CDA10 are:
• Check that the switch, located on the press or in the electrical cabinet/panel, is in the OFF (O)
position;
• Disconnect the press from the electrical mains;

• Disassemble cell TT1000 to be replaced, disconnecting it from all connectors;

• The load cell sensor does not need to be disassembled (if working);
• The encoder does not need to be disassembled (if working);
• Install the new sensing unit on its support [see relative paragraph];
• Connect the load cell sensor to the relative input;
• Connect the encoder to the load cell sensing unit
using the supplied adapter (Z);
• Connect the cables from the sensing unit to the
press, following the paragraph on connection
referring to the corresponding press model;
• The new load cell must be configured [see relative
paragraph].

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5.2.5 AUXILIARY CONNECTINGS

It is possible to use the press/equipment interface to connect different equipment to the control
unit, such as the BCC (Bad Crimp Cutter) and to have some operations managed by the relays
present on the electronic circuit.
Follow the connection and installation instructions present in the manual of the equipment to be
connected to the CDA10.

If the equipment is not produced by Mecal S.r.l., contact the manufacturer of the device and follow
the wiring diagram to the relays above. It is also necessary to use a 25-way D-Sub connector
(D25 series), not supplied.

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5.3 CHECKS AND VERIFICATIONS

Before starting the machine, carry out a series of checks and verifications in order to avoid
problems during its operation.

CAUTION

Before making any movement, make sure that there are no faults in order to
avoid damage to the machine. Before cancelling any faults, check the cause
and eliminate it.

5.3.1 GENERAL CHECKS ON THE MECHANICAL UNITS

HAZARD

These checks and verifications must be carried out with the machine stopped
and with all energy sources deactivated.

• Perform a general visual inspection of the various units making up the machine, making sure that
there are no particular mechanical faults or foreign bodies.
• Check that the machine parts and its guards have been properly anchored.
• Verify that the handling parts are properly lubricated if they need to be.

NOTE

Contact the Manufacturer immediately if any problems are detected.

CAUTION

Insulate the power cables by channelling them and divide them from the
signal cables to avoid electromagnetic interference. Follow the reference
standards.

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5.3.2 ELECTRICAL SYSTEM CHECKS

1. Check the electrical system in general and, in particular, check that all the cables inside the
electronic boards are correctly connected [see the relative electrical diagrams].
2. Check that the connector interfacing with the machine is correctly connected to the sensing
unit.
3. Check that the load cell sensor and encoder connectors are correctly connected to the
respective outlets on the sensing unit.

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5.4 UNIVERSAL INTERNATIONAL RECYCLING CODES

FOLLOWING INSTALLATION
Following the removal of machine packaging and its installation, remove the packaging from the
area surrounding the machine and dispose of it in accordance with the regulations in force. The
international recycling codes are indicated below.

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GENERAL INFORMATION 1

SAFETY 2

GENERAL DESCRIPTION 3

PACKAGING AND TRANSPORT 4

INSTALLATION 5

USE 6

DISMANTLING 7

MAINTENANCE 8

ATTACHMENTS 9

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6. USE
6.1 SWITCH
The equipment is dependent on the machine; therefore, it is necessary to use the press switch to
operate or switch off both. The switch has two positions:
• OFF position (O), in which the power supply is disconnected
• ON position (I), in which the power supply is connected.

6.2 ELECTRICAL CIRCUIT

The equipment is designed to be used in conjunction with the press machine. The sensing unit
contains the circuit that detects and analyses the crimping force and processes its profile. The unit is
connected directly to the press control unit, takes its power and disables it when monitoring failed
crimping.
Further clarifications on the electrical connections and the components used are available on the
relative wiring diagram and in the relative section.

NOTE

Since all machine movements are controlled by electrical and/or electronic

signals, it is advantageous if these signals are controlled by qualified
personnel.

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6.3 CONTROL AND SENSOR SYSTEMS

Below is the location of the control systems and of the sensors that are part of the equipment:

• Sensing and control unit

Equipped with a display to show the force curve
of the crimping and four front buttons for
choosing the settings and performing
configuration.
The unit disables the press if it detects failed
crimping.

• Load cell sensor

The sensor is chosen based on the maximum force the press can exert.

Sensor for TT and

P107 press models.

Sensor and amplifier for P040

and P080 press models.

NOTE

See the respective chapters for instructions on installing and adjusting the
sensing unit and sensor.

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6.4 MACHINE ARRANGEMENT

6.4.1 ENCODER CONFIGURATION
When the encoder is disconnected from the control unit, it emits an acoustic and visual signal. You
must therefore make sure that the encoder
connector is correctly connected to the control
unit. Then press a button on the unit.

The same signal is emitted when the press is in the

stand-by position [P.M.S.] and the encoder is in
position ≥ 0°. To avoid this disturbance, it must be
adjusted a few degrees.

Perform the following operations to set the encoder:

1. From the initial screen of the control unit (detail below), press the left button to access the
"Menu" item”.

2. Scroll to "Setup" and select it by pressing the right button [Select].

3. Scroll to "Installation" and select it by pressing the right button [Select].

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4. The "Encoder" item shows the real time value of the encoder angle. With the press in
stand-by [P.M.S.], turn the encoder until an angle
between 350,00° and 355,00° is set (to avoid
conflicts with "disconnected” Encoder status, do not
set the angle to 0,00° and do not set angles between
0,00° and 180,00°).
Tighten the headless screw, or grub screw, on the
hub (U) [follow the instructions in paragraph 5.1.6].
Activate the press three times and observe the results obtained at the end of each cycle. Values
must be stable ( ±5° ); otherwise, repeat the sequence, making sure that all screws are correctly
fastened.

6.4.2 ACOUSTIC SIGNAL SETTING

The control unit is equipped with an acoustic warning device which is activated whenever the press
is not crimping properly. The duration of the signal can be changed as needed. The default
duration is 0.8 seconds.
1. Access the installation menu: Menu → Setup → Installation.

2. Click on “Beep (s)” to change the value (press the scrolling keys).

3. Click on the right button [Save] to save.

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6.4.3 WEB CONNECTION

The control unit is equipped with a web server, which provides a network connection to operational
activities. It is possible to connect the unit to a network switch or directly to the Ethernet port of a
PC; in the latter case, it may be necessary to use a cross-over cable. See the Ethernet connection
diagram below for further information.

NOTA

Connections must be made by a qualified technician.

If the network has a DHCP server, the controller will try to get an IP address from the server (unless
it is disabled on the "Network Settings" page); otherwise, it will choose a default IP address.

To verify the IP address associated with the controller, go to the system information menu:
Menu → Information → System Information

In the example, the IP address set is 192.168.1.14. Type it on the PC browser to connect directly to
the controller web page. See the image on the next page, which mirrors the main screen.

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If the connection fails, check that the controller's network interface has the IP address set and that
it is in the same subnet as the PC and or server. Also check if your PC or server functions as a DHCP
server.

To set the DHCP, IP address and Subnet Mask, go to the network menu:
Menu → Setup → Installation → Network Settings

After setting the values, save and restart the control unit.

NOTE

If the unit does not connect to the network, contact your network
administrator and/or a qualified technician.

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6.4.4 NETWORK SETTING

Click on "Network” on the sidebar of the main web page to enter the "Network Settings" menu.

The "Network Settings" web page lets you modify the IP address parameters, the same ones that
can be configured by the control unit and which are described in paragraph 6.4.3. In addition,
it is possible to change the Host name and set a password for the control unit (Admin Password).
The password allows you to protect the configuration pages from unauthorised access. If it is
entered, the protected pages will ask for a username and password.
The default username for accessing protected pages is Admin.
The password is the one set by the user in the "Admin Password" box.
To save changes made to the data on this page, press the "Save Config" button.

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6.4.5 SOFTWARE UPDATE

Make sure that the operating software is up to date with the latest version available, as the
manufacturer may have issued a new release in order to fix bugs or add new features.
To verify the installed version, go to the system information menu:
Menu → Information → System Information

Software installation is performed via network connection, without needing to directly access the
control unit, uploading the new software file from a PC to the web page of the web server
embedded in the device.
After having completed connection to the web network (paragraph 6.4.3), follow the procedure:

1. Click on "Network” on the sidebar of the main web page to enter the “CFA Settings” menu and
click on the “Software” link.

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2. Click on “Choose file”, select the file from the desired folder and then click on “Upload”.

It takes a few seconds to transmit the file and restart the device to install the new software. During
this time, the backlight on the controller screen flashes.

When the operation is complete, the controller will run the new software.

NOTE

A password and user name may be required to access the page. The two fields
are empty by default, even if a password has been set on the network page.

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6.4.6 PEAK FORCE CALIBRATION

The control unit makes its decisions (Pass/Fail) by comparing the reference force curve profile,
detected during the learning process, with the profile of the force curve of each crimp. For this
reason, the load cell must not be calibrated, but must only be repeatable. The load cell can be
calibrated if the operator needs to make more accurate peak force measurements. If you
have a preloaded force sensor that comes with a calibration certificate, the values on the calibration
certificate can be entered in the table on the "Sensor Calibration" page by following this procedure:

1. Click on "CFA Settings” on the sidebar of the main web page to enter the “CFA Settings” menu
and click on the “Sensor Calibration” link”.

2. Enter the data in the table and send it to the controller, clicking on “Submit”.

The transducer capacity value

can also be viewed or edited on
this page. This value is used
by the mathematical model in
the controller to translate the
voltage readings from the
sensor into load values, which
can be found in the calibration
table to produce force
measurements. The
transducer capacity is
automatically updated by the
system if the auto-calibration
function is activated from the
controller menu.

The load cell can be calibrated

approximately by changing the
transducer capacity value. If
you wish to change the overall
gain of the model to correct the
peak force display, use the

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formula:

For example: If the display shows a peak force of 10kN but you want a displayed value of 8kN,
change the transducer capacity value as follows: 3162 * 8 / 10 = 2530

It is also possible to view or edit the calibration notes. To save changes made to the data on this
page, press the "Submit" button.

6.4.7 CRIMP FORCE DETECTION HISTORY

The "Force History Table" page shows the count of the forces detected by the controller. Follow this
procedure to access the screen:

1. Click on "Network” on the sidebar of the main web page to enter the “CFA Settings” menu and
click on the “Force History Table” link.

The table will then appear (see next page).

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These values can be used for

service requests and/or to
establish a service program
dedicated to the machine.

The counters can be reset or

adjusted, but an authorisation
code must be provided.

Furthermore, the data can be

displayed graphically by clicking
on the "History Plot" hyperlink
which shows the histogram:

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6.4.8 OPERATING PASSWORD SETTING

An operating password can be set to prevent changes to the control unit settings. The
password protection and the password to install the software update are disabled by default.

Follow these steps to set the password:

1. Click on "Network” on the sidebar of the main web page to enter the “CFA Settings” menu and
click on the “Operating Password” link.

2. Enter the password, select the type of protection you want to give and click on "Submit".

If the code is set to

"0000", the password
system will be disabled,
while the system will
operate if any other code
is set.

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6.5 MACHINE USE PROCEDURES

6.5.1 INITIAL CHECKS
The operator must check the following before starting the machine:

• Make sure that all power sources are properly connected to the respective power supply
networks.
• Make sure that there are no foreign bodies in the radius of action of the machine.
• Verify correct functioning of the safety devices present (emergency buttons, etc.).
• Check that the machine is not in maintenance or cleaning status.
• Make sure that the switch is in the ON position (I).
• Verify that the press ready status light is on.
• Make sure that the load cell is correctly configured with the settings for use with equipment.

6.5.2 CONNECTING POWER

Before starting the machine:

• Connect the electricity.

• Set the switch on the electrical box of the press to the ON position (I).

6.5.3 OPERATING MODE

The control unit acquires and analyses the crimping force curve profiles. Whenever incorrect
crimping is detected, the machine emits a beep and disables the press until the operator intervenes.

6.5.4 SWITCHING OFF THE MACHINE

To switch off the machine, set the switch on the electrical box of the press to the OFF (0) position.

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6.6 USE
6.6.1 LEARNING
The control unit signals correct or incorrect crimping, comparing the force curve profile with a
reference force curve that records during the learning phase.
In the learning phase, the press, the applicator and any accessories must be installed as in
production.

NOTE

The control unit does NOT have integrated knowledge of how the correct
crimping profile should look.

It is the operator’s task to carry out three learning crimpings and to check
that they are correct before proceeding with production.

Some samples are made which must be checked in the laboratory, for example for the crimping and
pull-out height measurements. The learning phase is carried out once the quality of crimping
has been ascertained.

Enter the menu to start the learning procedure:

1. Menu → Start Learning and confirm the start of the phase with the right button (YES).

2. The title “Start Learning” will appear on the screen. It will now be possible to make the three
learning crimpings.

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3. Sequence of learning steps: three crimpings.

See paragraph 6.6.5 to set the parameters for evaluating the force curves.

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6.6.2 PRODUCTION
The main screen on the control unit display shows the force and reference curves.

The parameters shown are as follows:

P:1 CORRECT crimping (since last learning)
F:0 INCORRECT crimping (since last learning)
16.7kN=OK Applied force measured and result [OK/NO]
51/100 PASS Non-corresponding result (51) and tolerance limit (100)

Press the right [More] button to display the additional information.

Count: 5 Total performed crimping counter (5)

Production Pass/Fail Status of last crimping Correct/Incorrect
Variation:363/100 Non-corresponding result (51) and tolerance limit (100)
Headroom:18% Headroom (margin between nominal level and maximum manageable
value)
13882N 152mJ Applied force and energy in the crimping

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6.6.3 HOW CRIMP FORCE MISMATCH IS CALCULATED

The figure below shows a reference curve (in red) and a superimposed force curve for comparison
(blue). In this example, the blue curve could be typically associated with a crimping error on
insulation.

The figure below shows the area that is non-corresponding, which is given by the difference
between the two curves. The controller measures this area for each crimping cycle. The
algorithm does not take into account whether the error occurs above or below the reference curve,
but all errors are accumulated positively.

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The figure below shows the reference area, which is measured and used as a divider in calculation
of the non-correspondence. This helps to "normalise" the variation calculation, so that the
result for incorrect crimping on a large terminal is similar to the result for incorrect crimping on a
small terminal.

The crimping force curve non-correspondence is calculated using the formula:

Non-correspondence = 1000 * Non-correspondence area / Reference area.

Non-correspondence is a number without dimensions, that is always positive, that has no unit of
measure and the multiplication of the area by thousand is used to resize the value obtained to
make it easily manageable as an integer. A result that coincides with zero represents a perfect
correspondence between the curves, while the more the values increase, the more there are
greater differences between the force curves. Peak force does not directly influence the
calculation of non-correspondence, as can be seen from the above examples: curves with identical
peak forces can have a high discrepancy. The control unit shows the peak force as a secondary
value in the basic process configuration. If data is recorded for each job, problems can be identified
before the pull-out tests are performed.

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6.6.4 CRIMP FAIL

The main screen on the control unit display shows the crimping error.

1. Press any button to return to the production screen.

2. Press the right [More] button to display additional information on the incorrect crimping.

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