FRIEDHELM LOH Rittal L8 Operating Instructions Manual

Crimping machine

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Crimping machine L8

AS 4050.452

Operating instructions

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Page 1 Crimping machine L8 AS 4050.452 Operating instructions...
Page 2: Table Of Contents
Contents Contents About this documentation............3 General safety instructions ............4 Intended use......................4 The following is not permitted ................4 Machine dangers ....................4 Operational hazards..................... 4 Hazard sources ..................... 4 Safety equipment ....................5 Warning signs at and on the machine or components........5 Residual risks ......................
Page 3: About This Documentation
1 About this documentation About this documentation The warnings in this documentation are structured differently depending on the severity of danger. Warning! Possible risk of fatality! Notices with the signal word "warning" warn you about situations which could lead to fatal or serious injuries if you do not pay attention to the notices specified.
Page 4: General Safety Instructions
2 General safety instructions – Bullet points are indicated with dashes. Operating instructions in other languages can be found on our website: Click here! General safety instructions Intended use The crimping machine L8 is an electro-pneumatic crimping machine designed ex- clusively for stripping insulation from flexible conductors in accordance with DIN 60228:2005 and for crimping loose wire end ferrules with plastic collars (size 0.5 –...
Page 5: Safety Equipment
2 General safety instructions Caution! Risk of injury due to missing safety equipment! ◼ Never remove safety equipment or decommission it by making changes to the machine. Safety equipment Safety equipment is installed to protect personnel. The operating company is obliged to inspect the safety devices annually.
Page 6: Noise
3 Device description – Deploy only original fuses with the specified amperage. – Knowledge of the local, operational safety and accident-prevention regulations. – All notes on machines must be kept legible, and renewed when necessary. ◼ Notify the manufacturer without delay should defects become apparent, provid- ed they were not caused intentionally.
Page 7: Technical Data
3 Device description Fig. 2: Interior view Setting button Separating unit Vibrating conveyor (VC) upper part Touch display Twist lock Maintenance unit Insertion funnel Mains filter module Opening wedge S1 setting Stripped insulation scrap container Hexagonal spanner Tool unit (ferrule holding unit, crimping unit) Cable feeding unit Technical data AS crimping machine L8...
Page 8: Operating Instructions
4 Operating instructions AS crimping machine L8 Degree of protection IP 20 Cycle time approx. 1.0 s Continuous sound pressure level ≤70 dB(A) Dimensions (W x D x H) 390 x 330 x 460 mm Colour RAL 9003 Weight 31 kg Interfaces Touch display Operating environment...
Page 9: Switch On The Machine
4 Operating instructions Fig. 3: Maintenance unit Setting button Manometer Filter element Container Manual drain Switch on the machine ◼ Switch on the mains switch at the mains filter module. Menu 1 appears in the display. Menus   – Up or down –...
Page 10 4 Operating instructions ◼ Select E. Cursor flashes.   ◼ Set the value with ◼ Confirm E. To load the infeed belt:  – When the key is held down, the VC value increases to the highest value.  –...
Page 11: Conductor Insertion / Conductor Cutting
4 Operating instructions Insulation stripping program Stripping and crimping Stripping only After switching on the machine, the "Stripping = 0" program is set. If the "Stripping = 1" program is selected, this is displayed in the Operating menu. Quantity counter and processing time Tot.
Page 12: Tools
5 Tools 40 mm Correct Incorrect Inclined cut Correct Protected conductor Incorrect Pulled-out conductor Crushed conductor Recessed conductor Tab. 1: Conductor insertion / conductor cutting Tools Ferrule feed The ferrule feed consists of the vibrating conveyor upper part, the separating unit and the feed pipe.
Page 13: Triggering Unit
5 Tools Vibrating conveyor (VC) Wire end ferrule upper part Separating unit 1.0 / 8 N 0.75 – 1.0 1.0 / 8 S 1.5 / 8 N 1.5 / 8 S 2.5 / 8 N 2.5 / 8 S-XS Tab. 2: Setting overview Triggering unit ◼...
Page 14: Maintenance
6 Maintenance Depending on the strength and thickness of the insulation, the cam must be ad- justed in the "+" or "–" direction. ◼ To cut less, move the cam in the "+" direction; to cut more, move the cam in the "–"...
Page 15: Weekly Maintenance
6 Maintenance Fig. 6: Stripped insulation scrap container Stripped insulation scrap container Weekly maintenance Blowing clean the feed guide ◼ Remove the feed guide: unscrew the handle, turn the guide counter-clockwise and remove upwards. ◼ Remove the feeding material from the feed guide. ◼...
Page 16 6 Maintenance Cleaning the machine interior ◼ Open the front panel. ◼ Remove the stripped insulation scrap container. ◼ Clean the machine interior using a brush and a vacuum cleaner. Attention! Property damage! Do not use compressed air to clean the machine interior. Cleaning the stranded wire fixture ◼...
Page 17 6 Maintenance Fig. 9: Holding pliers Holding pliers Cleaning the insulation stripping unit ◼ Swivel the tool unit to the right. ◼ Clean the entry hole in the insulation stripping unit carefully with a soft, suitable brush (e.g. pipe cleaner) and methylated spirits. ◼...
Page 18: Monthly Maintenance
6 Maintenance Fig. 11: Insulation stripping unit Control area Limit stop Stripping carriage Checking the compressed area setting To ensure correct functioning of the machine, the pressure set at the maintenance unit must lie in the range 5.0 to 5.5 bar. Fig.
Page 19 6 Maintenance Fig. 13: Stranded wire fixture Stranded wire fixture pivot Castor Holding pliers ◼ Lightly oil the holding pliers at the pivot and the contact surface. Fig. 14: Holding pliers Pivot and the contact surface Ferrule holding unit and crimping tool ◼...
Page 20 6 Maintenance ◼ Check the crimping tool castors for free movement. ◼ Lightly oil the castors pivot. ◼ Lightly oil the guide pin. ◼ Reinsert the stranded wire fixture. Ensure that the guide shaft sits in the hole of the stranded wire fixture. ◼...
Page 21: Quarterly Maintenance
6 Maintenance Crimping tool Ferrule holding unit Distance ring Guide shaft Stranded wire fixture Fig. 17: Ferrule holding unit and crimping tool Guide pin Crimping tool castor Ferrule holding unit castor Quarterly maintenance Lubricating the swivel carriage ◼ Pull the stranded wire fixture forwards. ◼...
Page 22: When Required
7 Troubleshooting When required Compressed-air maintenance unit ◼ Drain the condensate water. To do this, press the drain plug upwards. If the container is soiled, it can be cleaned with water. ◼ To do this, close the compressed-air feed and unscrew the container. Attention! Property damage! Clean the container only with water.
Page 23: The Wire Is Only Stripped
7 Troubleshooting The wire is only stripped. Program 3 "Stripping" is selected ◼ Correct the setting. Large number of rejects Insulation stripping blade damaged or installed incorrectly. ◼ Repair or replace blade. Stripped insulation scrap present between the tool unit and the right limit stop. ◼...
Page 24 7 Troubleshooting "VC-error tempr." – Vibrating conveyor guide activation: Shutdown, temperature too high "VC-RS485 Tim.Out" – Vibrating conveyor guide activation: Timeout, check the connection cable "VC-error 230V" – Check the mains voltage – Vibrating conveyor guide activation: 230 V missing "VC-error 115V"...
Page 25 7 Troubleshooting "S4-Toolslide front = 1" – Check S4 and Y1. "S5-Toolslide back = 0" – Check S5 and Y1. "S5-Toolslide back = 1" – Check S5 and Y1. "LS10-fer.missing" – Ferrule missing, check S10 "LS10-fer. present.=1" – Remove ferrule, check S10 "ex.start n.
Page 26: Pneumatic Connection Diagram
8 Pneumatic connection diagram Pneumatic connection diagram We reserve the right to make technical m odifications. Rittal Crimping machine L8...
Page 27: Electrical Connection Diagram
9 Electrical connection diagram Electrical connection diagram Valve block Touch terminal RS5485 Main valve Ferrule holding unit Wire-holding pliers Abiso crimping cylinder Ferrule guide Ferrule contact Swivel cylinder Rear slide Tool slides Front slide Illumination Start Position crimp Flap Text display connection Keyboard connection Ritta l Crimping machine L8 We reserve the right to make technical m odifications.
Page 28: Spare Parts
10 Spare parts Spare parts Designation Model no. AS Insulation stripping blade kit, titanium 4050466 Wire end ferrules 0.5 mm², 8 mm long 4050730 Wire end ferrules 0.75 mm², 8 mm long 4050731 Wire end ferrules 1.0 mm², 8 mm long 4050732 Wire end ferrules 1.5 mm², 8 mm long 4050733...
Page 29 ◾ Enclosures ◾ Power Distribution ◾ Climate Control ◾ IT Infrastructure ◾ Software & Services You can find the contact details of all Rittal companies throughout the world here. www.rittal.com/contact RITTAL GmbH & Co. KG Auf dem Stuetzelberg · 35745 Herborn · Germany Phone +49 2772 505-0 E-mail: info@rittal.de ·...

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As 4050.452