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Mecal FAKRA Operating Instructions Manual

Project restyling operating instructions
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Mecal Srl
Sede legale e Stab.: Strada per Felizzano, 18 - 15043 Fubine (Al)
Tel. (0131) 792792 - Fax (0131) 792733/792734Cap. Soc. € 500.000 int.vers.
Registro delle Imprese di Alessandria n. 11690 - CCIAA Alessandria - REA N. 153887 - N. Meccanografico AL002563
Codice Fiscale 01328270069 – Codice ISO: IT - Partita Iva: 01328270069
ISTRUZIONI OPERATIVE MINIAPPLICATORE RESTYLING
PROGETTO FAKRA
FAKRA PROJECT RESTYLING OPERATING
INSTRUCTIONS
FAKRA OUTER DIRITTO (maschio e femmina) PER CAVO:
RG174, RTK031, RG58/59
Miniapplicator Operating instructions Created by Mecal s.r.l.
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Summary of Contents for Mecal FAKRA

  • Page 1 Codice Fiscale 01328270069 – Codice ISO: IT - Partita Iva: 01328270069 ISTRUZIONI OPERATIVE MINIAPPLICATORE RESTYLING PROGETTO FAKRA FAKRA PROJECT RESTYLING OPERATING INSTRUCTIONS FAKRA OUTER DIRITTO (maschio e femmina) PER CAVO: RG174, RTK031, RG58/59 Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 2 Preferred by Professional EDS Specialist These instructions have been created in october 2009 and Mecal reserves the right to modify it at anytime. Furthermore, the pictures shown might not represent the latest configurations or special versions manufactured to satisfy special customers needs.

  • Page 3: Table Of Contents

    ......................58 8.1) C (MRSP)..............58 AMME SU ESTYLING PNEUMATICO 9) MANUTENZIONE .......................59 9.1) P .....................59 ARTICOLARI DI RICAMBIO 9.2) E ....................60 SEMPIO DI DOCUMENTAZIONE 9.3) P .....................62 ULIZIA E LUBRIFICAZIONE 9.4) I ......................63 MMAGAZZINAMENTO Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 4 OSTITUZIONE PARTICOLARI DI RICAMBIO 9.5.1) Sostituzione matrici di aggraffatura e taglio..............64 9.5.2) Sostituzione supporto terminale “Inner” ................66 9.6) D ....................68 EMOLIZIONE E SMALTIMENTO 10) RICERCA GUASTI E RISOLUZIONE PROBLEMI ..........69 11) ASSISTENZA POST VENDITA ...................73 Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 5 9.4) Storage ............................63 9.5) Substitution spare parts ......................64 9.5.1) Substitution crimping and cutting ................64 9.5.2) Substitution contact support "Inner” .................66 9.6) Demolition and disposal ......................68 10) Problem shooting ........................69 11) After sales service ........................73 Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 6: Avvertenze Importanti

    • The applicator turns smoothly without sticking in any way • The terminal is correctly placed on the anvil, in line with the same and the other crimping and cutting parts Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 7: Simbologia

    SALVATAGGIO: questo simbolo viene utilizzato per indicare alcune parti del manuale in cui vengono riportate note o consigli dove occorre effettuare un salvataggio dei dati dell’attrezzatura SAVE: this symbol identfies any portion of this manual that refers to data that should be saved. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 8: Identificazione

    2) Identification P/N terminale del cliente o fornitore Terminal customer reference (Part Nr.) Modello miniapplicatore relativo al P/N del terminale Mecal’s Miniapplicator code (related to the above mentioned terminal) Altezza di aggraffatura (CHR) Crimping Height (CHR) Posizione della ghiera (INDEX) riferita all’altezza di...

  • Page 9: Descrizione Del Prodotto

    (not related to each other) Applicazione Miniapplicatore FAKRA su presse – FAKRA Miniapplicator application on the presses...

  • Page 10: Caratteristiche Tecniche

    RG174, RTK031, RG58/59 Sistema di alimentazione: aria 5/6 Bar Feeding system: air pressure 5/6 Bar Peso: 7,8 kG ( 17,2 lb) Weight: 7,8 kG ( 17,2 lb) Dimensioni: W320xH145,5xD370 W12,5"xH5,72"xD14,5" Dimension: W320xH145,5xD370 W12,5"xH5,72"xD14,5" Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 11: Ispezione Alla Consegna

    • • In caso di anomalia avvisare Mecal In case of damages and/or missing entro e non oltre i 10 giorni dalla data di parts, please notify Mecal within 10 days ricevimento from receiving the applicator • • L’imballaggio deve essere smaltito...

  • Page 12: Installazione

    ± between the applicator locking base and the T coupling is mm 135,8 ( 0.01mm) Note: MECAL presses are delivered already in compliance with the above mentioned setting 5.1) Installazione Miniapplicatore 5.1) Miniapplicator Installation ATTENZIONE: tutte le operazioni di installazione vanno effettuate con pressa in emergenza o spenta.
  • Page 13 • Mecal Miniapplicator are delivered with the rubber Remove the rubber spacer spacer inserted between the continuos adjusting head and the body, to protect its during transportation. Remove the rubber spacer when installing the applicator. • Place the tool on the fixing plate A, line up the Magnum’s D base with the B hook and tighten up...

  • Page 14: Collegamento Pneumatico Ed Elettrico

    ATTENZIONE: tutte le operazioni di collegamento connettori vanno effettuate con pressa in emergenza o spenta e senza aria nell’impianto. ATTENZION: all connection operations must be carried out connectors with press in emergencies or off and no air in the system. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 15: Schema Pneumatico

    5.3) Schema pneumatico 5.3) Pneumatic drawing Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 16: Inserimento Terminale

    Free the cluch by means of the lever B , place the terminal in the guide A, push it until it will be hooked by the pawl C and then tighten the cluch by means of the lever B Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 17 Should the obtained crimping height vary from the data on the identification plate, please check the press set up according to paragraph 1 & 5. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 18: Regolazioni

    è garantito mediante la ghiera B con un processo di regolazione identico a quello descritto precedentemente per la ghiera A. Nel caso in cui non siano state fornite specifiche di aggraffatura, Mecal suggerisce di impostare la ghiera B sulla posizione 0 incrementandone il valore fino a raggiungere il risultato voluto.
  • Page 19 ATTENTION: the example of "Continuos adjusting head" refers to ring back with a resolution of 0.01mm. For other models of ring MECAL marketed by the principle of adjustment is the same taking into account that the resolution is 0.02 and 0.03mm I dati rilasciati e dichiarati sul Technical Data Sheet sono stati rilevati in laboratorio di collaudo con pressa Mecal P107C tarata ad un’altezza di lavoro (P.M.I.) di 135,8mm...

  • Page 20: Regolazione Passo Terminale

    CH4. Ruotando il grano B in senso orario si riduce il passo del terminale, in senso antiorario si aumenta. Terminata la regolazione serrare il dado di bloccaggio A. La velocità d’avanzamento si puo’ controllare intervenendo sul regolatore di flusso dell’aria C. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 21 For proper operation, verify that the air pressure in the system is 5 / 6 BAR ATTENZIONE: tutte le operazioni di regolazione vanno effettuate con pressa in emergenza o spenta. ATTENZION: any adjustment must be performed after having made sure that the press is turned off. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 22: 1) Regolazione Sensore Avanzamento Terminale

    6.2). When the operation lever sensor signal B must stop and give consent. If this does not happen loosen the locking screw C, intervene sensor lever B by adjusting the position and tighten the screw C. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 23: 2) Sensore Controllo Bandella Terminale

    The optical sensor A (SQ5) serves to verify the presence of the strip B of ligation terminal Outer C. It is always active and has no adjustments. In the moment when the strip ends the sensor deactivates the signal sending error in the press. Replace the coil over with a new one. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 24 (incudine, matrice rame, matrice isolante). The adjustment of the terminal on anvil axis K is also known as fine and serves to position the terminal perfectly aligned with the details of crimping Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 25 ATTENZIONE: tutte le operazioni di regolazione vanno effettuate con pressa in emergenza o spenta. ATTENZION: any adjustment must be performed after having made sure that the press is turned off. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 26: Allineamento Terminale Con Matrici

    6.4) Allineamento terminale con matrici 6.4) Terminal alignment matrix 6.4.1) Matrici superiori 6.4.1) Wire and insulation crimper Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 27: 2) Matrici Inferiori

    The alignment of the anvil with the terminal T defines the footprint of crimping the bottom of the contact, the length of the witness from the cutting strip and the positioning for the centering of the control system (presence piece, linearity with working axis, anomalies). Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 28 / support to determine the footprint of seaming and the distance of the witness cutting of the terminal from the strip of ligation. Loosen the lock nut and adjust the screw to control B. Found the ideal position, tighten the lock nut A. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 29: 3) Lama Di Taglio Inferiore

    The mini that are not updated with the front adjustment (B) shall be removed from the press and require action on the screw F (loosen), adjust the screw (C) and tighten the screw (F). Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 30 The adjustment of the cutting pressure can act on the front blade and separate the terminal from the strip. This position is important because it allows a free passage to the cable with the crimped terminal in the terminal inner Outer. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 31 Nel caso NON vada bene ripetere l’operazione dall’inizio • Nel caso la regolazione è OK riportare il selettore della centralina su CONTINUOUS tenendo premuto il pulsante F per circa 2 sec. La spia verde deve essere spenta. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 32 Verificare che la pressione nel circuito è pari a 6 BAR ATTENZION: any adjustment must be performed after having made sure that the press is turned off. Check that the pressure in the circuit is 6 BAR Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 33: Bloccaggio Terminale

    • • Serrare il dado di bloccaggio B Check the operation of the solenoid valve • Verificare l’operazione intervenendo EV4 intervening manually activating the manualmente sulla elettrovalvola cylinder C attivando il cilindro C Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 34: 2) Sensore Blocco Terminale, Sensore Terminale Mancante

    A e attiva un nuovo Sensor B NO OK + sensor C OK: progress avanzamento del terminale riprendendo il next terminal. ciclo di lavoro dall’inizio. Sensore B NO OK + sensore C OK: avanzamento terminale successivo. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 35: Regolazione Centraggio Posteriore

    The centering bushing rear serves to center the terminal and ensure the coaxiality with the central support for the inner. The X dimension of about 1 mm, it is necessary to move the terminal during the progress. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 36 To encourage and facilitate this adjustment is to remove the miniapplicator from the press and keep active with pressure pneumatic connectors in the circuit. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 37: Inner

    6.8) Regolazione posizione Outer e guida 6.8) Position Adjustment of Outer Inner Inner guide Fig.1 Fig.2 Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 38 If NOT go well repeat the operation from the beginning • If the setting is OK turn the dial on the controller CONTINUOUS holding down the F for about 2 seconds. The green light should be off. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 39: 1) Regolazione Sensore Per Posizione Outer

    LED reading B is turned on. Loosen the locking screw A and move the sensor C to obtain the position sensor corretta.Il C (SQ6) serves to ensure that the cylinder ports CP1 contact Outer in the working position to allow the entrance of the cable Inner. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 40: 2) Allineamento Guida Centraggio Con Supporto Inner

    Impostare la macchina STEP BY STEP mediante selettore su centralina F tenendo premuto per circa 2 sec. La spia verde deve essere accesa • Effettuare un paio di cicli completi per verificare la corretta regolazione • Nel caso NON vada bene ripetere l’operazione dall’inizio Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 41 Verificare che la pressione nel circuito è pari a 6 BAR ATTENZION: any adjustment must be performed after having made sure that the press is turned off. Check that the pressure in the circuit is 6 BAR Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 42: Gruppo Sensore Posizione "Inner

    FAKRA. The X dimension determines the final position of the Inner (A) with respect to the contact Outer (B). Usually it is a value given by the manufacturer's specifications for the terminal and FAKRA process Fig.1 Fig.3...
  • Page 43 (Fig.4) and is moved by a cylinder D to allow overtravel of rest. And also the support is preloaded by a spring system and acts as a sensor positioning F. The adjustment of the X (Fig. 1) occurs through the shock C. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 44: 2) Regolazione Sensore Posizione Inner

    Optimum setting is defined by the LED sensor G when the system is in stop at B. In the case turning on in advance repeat the adjustment operation from the beginning. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 45: 3) Verifica Anomalie Durante Inserimento Outer Su Inner

    D is released by turning off the sensor position G. In this case, the cable locking pliers are opened, freeing the inner cable, and the system will reset remaining pending to allow the insertion of a new inner cable or to check the recovery of the previous one. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 46: Inner

    EV1 chiusura delle pinze di bloccaggio cavo B • Verificare la linearità tra il punto A e il punto D • Effettuare la regolazione allentando le viti di bloccaggio C e intervenire su pinze B Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 47 Verificare che la pressione nel circuito è pari a 6 BAR ATTENZION: any adjustment must be performed after having made sure that the press is turned off. Check that the pressure in the circuit is 6 BAR Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 48: 1) Regolazione Chiusura Pinza Bloccaggio Cavo "Inner

    D. Intervene again on the adjustment if the cable is be marked D (too much clamp pressure C) or tends to slide (little clamp pressure C). Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 49: 2) Regolazione Sensore Pinza Bloccaggio Cavo "Inner

    LED A sensor D (SQ4) should be lit. In case it was necessary to perform an adjustment, loosen the locking screw B and D move the sensor (SQ4) downwards or upwards. After adjustment, tighten the lock screw B. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 50: Ciclo Di Lavoro (Manuale)

    If SQ2 and SQ8 are NO OK the machine goes into emergency • If SQ2 is OK and SQ8 is NOT ok to reset the machine and makes a new advance of the terminal on the anvil / support. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 51 (alloggio inner) sul supporto contatto Inner. Translation of the separate terminal toward the rear of the applicator. The centering unit allows you to drive home inside of the contact (housing inner) on the Inner contact support. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 52 Excess Inner contact support. This position is adjustable (see chapter 6.9.1), determines the share defined by the technical specifications of the inner inside the Outer. STEP 5 Posizionamento pinze di centraggio. Positioning centering grippers Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 53 STEP 6 Chiusura pinze di centraggio Closing centering gippers STEP 7 Inserimento contatto Inner, attivazione sensore di posizione, chiusura pinza bloccaggio cavo. Inner contact engagement, activation position sensor, locking pliers locking cable. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 54 STEP 8 Apertura pinze di centraggio Opening centering gippers STEP 9 Ripristino pinze di centraggio. Inner vincolato su supporto con sensore OK Restoring centering grippers. Inner bound on media with the OK sensor Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 55 If the Inner sensor is OK the press performs the working cycle of the crimping terminal. If the sensor is NO OK system is released and the cycle starts again from STEP 6 Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 56 Rimuovere il cavo aggraffato dalla zona di lavoro Remove the crimped cables from the working area STEP 13 Sensore di verifica presenza e assialità terminale Outer Sensor checks presence and axial terminal Outer Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 57 STEP 14 Avanzamento terminale per nuovo ciclo di lavoro Advancement terminal for new work cycle Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 58: Posizione Camma

    In the pneumatic version there is only one type of cam. PRE FEED CAM: used in position A to work with this terminal and press with a working stroke of 40mm or in position B, in press working stroke 30mm Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 59: Manutenzione

    “Documentazione”. Make sure that model & serial number are the ones of the applicator you’re interested to. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 60: Esempio Di Documentazione

    - the components with a higher rate of wearing. Please refer to the numeric reference of each component to identify the part number of the component to be ordered. Pag.1 DATASHEET Pag.2 Distinta base – Parts list Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 61 MECAL suggest to save in a PC the files related to component list, data sheet and drawings. Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 62: Pulizia E Lubrificazione

    The miniapplicator must be cleaned and lubricated every time it is removed from the press or every 8 working hours. Consigliato da MECAL grasso AUTOL TOP 2000 Suggested lubricating grease AUTOL TOP 2000 1) Rimuovere il terminale con la bobina e 1) Remove the applicatore from the press l’applicatore dalla pressa (vedi nota 9.4)
  • Page 63 NOTE: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 64: Sostituzione Particolari Di Ricambio

    Munirsi di chiavi inglesi o a forchetta e di chiavi a brugola necessarie per lo smontaggio e il rimontaggio • Munirsi di uno straccio pulito, del lubrificante (possibilmente quello consigliato da Mecal vedere punto 9.3), schema pneumatico nel caso fosse necessario scollegare tubi dell’aria. •...
  • Page 65 • Bring wrenches or fork and Allen key required for disassembly and reassembly • Bring a clean, oil (preferably one recommended by Mecal see paragraph 9.3), pneumatic scheme in case you need to disconnect air hoses. • Exploded applicator with specific references and separate basis for comparison of parts UPPER CRIMPERS •...

  • Page 66: 2) Sostituzione Supporto Terminale "Inner

    • Bring or fork spanners and allen keys needed for disassembly and reassembly • Bring a clean, oil (preferably one recommended by Mecal see paragraph 9.3), pneumatic scheme in case you need to disconnect air hoses. • Exploded applicator with specific references and distinct basis for comparison of the pieces •...
  • Page 67 Fig. 1 Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 68: Demolizione E Smaltimento

    Alluminio CER 170402 Materiale plastico CER 170203 Olio esausto CER 130205 Parti elettriche CER 160214 Questi codici sono indicativi ed è responsabilità del proprietario dell’attrezzatura verificare le corrette modalità e codifiche di smaltimento Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 69: Ricerca Guasti E Risoluzione Problemi

    (side-feed) or at towards the anvil. • the wire/insulation barrel (end- The brake on the feeding guide is feed). not operating. • Make sure the feeding guide brake is on. Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 70 (vedi punto 6.1) • • La sezione del cavo non è Verificare che la sezione del cavo corretta utilizzato quella corrispondente alla posizione di lavoro Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 71 The downtime will lock the drawer of the pneumatic valve (Ref.180). If the problem persists, replace the pneumatic valve Ref180 and see if there are impurities in the air circuit Miniapplicator Operating instructions Created by Mecal s.r.l.
  • Page 72 Miniapplicator Operating instructions Created by Mecal s.r.l.

  • Page 73: Assistenza Post Vendita

    Fax +39 0131 792733 e_mail corrado.aceto@mecal.net For any further clarifications, please feel free to contact Mecal : Tel: +39 0131 792755 (time 8.00 – 12.00 / 13.30 – 17.30 Monday to Friday) Mobile: +39 335 8737156 Fax +39 0131 792733 e_mail corrado.aceto@mecal.net...

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