Danfoss Control C.2 Operator's Manual
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Danfoss Control C.2 Operator's Manual

Danfoss Control C.2 Operator's Manual

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  • Page 2 Imprint Manufacturer: UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50-52 D-61184 Karben Germany Phone: +49 (0) 60 39 / 91 71 - 0 Fax: +49 (0) 60 39 / 91 71 - 181 This Operating Manual of the machine is a translation; the origi- nal is in German.

  • Page 4: Table Of Contents

    Contents About this document ................... 6 1.1 Storage ......................6 1.2 Figure presentation ..................6 1.3 Abbreviations ....................7 1.4 Accessories ....................8 Safety instructions ....................9 2.1 Presentation of warning notes ............... 9 2.2 Safety instructions ..................9 2.1 Use in compliance with intended purpose ............. 9 Control description ....................
  • Page 5 8.3 Check with calliper (Option) ................ 55 8.4 Calibration ....................58 Error messages ....................61 9.1 Error message “Oil filter contaminated” ............61 9.2 Backup and restore CONTROL C.2 ............62 Annex ......................... 65 10.1 Accessories (retrofittable) ................65 10.2 Spare parts list .................... 66...

  • Page 6: About This Document

    About this document The control unit "Danfoss Control C.2" is consistently designated as control in this Operation Manual. This Operation Manual includes important notes on how you operate your machine and control safely, properly and economically. Storage This Operation Manual is a document also applicable in connection...

  • Page 7: Abbreviations

    The individual elements in the figures are described from left to right and from top to bottom. The values shown in the figures are given as examples and may differ from actual values - depending on the machine type and the individual selection in the basic settings.

  • Page 8: Accessories

    UNIFLEX Label System UNIFLEX Transfer Software Industrial Crimp Calculator UPMS UNIFLEX Paperless Management System Accessories The machine may be fitted with accessories. A list of the available ac- cessories is included in the Annex, Section "Accessories".

  • Page 9: Safety Instructions

    Safety instructions Presentation of warning notes Warning notes in the Operation Manual warn against risks involved with the handling of the machine. Risk levels are identified as follows: The signal word HAZARD identifies an imminent hazard resulting in DANGER! serious injuries or death. This warning is supplemented by a triangu- lar hazard symbol.
  • Page 10 • Manipulations of the control unit; • Use in explosive environments; • Use in the open air WARNING! Use not in compliance with intended purpose Use not in compliance with the intended purpose impose risks for life and health. Consequences resulting from use not in compli- ance with the intended purpose shall be under the sole responsi- bility of the owner.

  • Page 11: Control Description

    Control description Operation and display elements (1) Emergency-stop button (2) Illuminated Motor On button (3) Illuminated Motor on button (4) Illuminated foot switch (5) Illuminated Open tool button (6) Illuminated Close tool button (7) Locking lever / angle setting (8) Control panel of control The illuminated buttons may be arranged the other way round, depending on the control version.

  • Page 12: Foot Pedal (Accessory)

    (1) LAN socket to connect a network. Regarding options for connec- tion to a network, please contact UNIFLEX. (2) 2 x USB sockets (for the use of memory media/ accessories cer- tified by UNIFLEX) Foot pedal (accessory) (1) Close machine pedal (2) Open machine pedal WARNING! Risk by fatiguing posture!
  • Page 13 the forming process, the left foot switch is used to open the tool. – Depth stop The tool is closed automatically when the workpiece acti- vates the depth stop by pressure. Press the button to open the tool. As soon as the forming diameter or forming pressure defined in the control is reached, the tool stops automatically.

  • Page 14: Control Operation

    Control operation The control features the following elements: • Buttons (blue circle) • Input fields (white field) • Value display (on grey background) The control is operated via the control panel: Tip on the relevant control element, • either with finger, or •...
  • Page 15 If figures or letters have to be entered, a keyboard or number field showing the permissible range of values will be displayed after touch- ing the control panel.

  • Page 16: Start Screen

    Start screen The following control screens are opened from the start screen: Workpiece table Crimp without workpiece table Machine settings The figures are described in more detail in the Sections below.

  • Page 17: Crimp Using Workpiece Table

    Crimp using workpiece table Start screen This screen is used to select the Danfoss product range from the list. Select settings from favourites. Select the product range Return to previous screen.

  • Page 18: Select Workpiece Specification

    Select workpiece specification This screen is used to select the hose type (workpiece) from the list. Confirm the highlighted workpiece. Return to previous screen. By making an entry in the Filter field, the workpiece list may be fil- tered according to a specific criterion.
  • Page 19 In this screen, you may select the matching coupling to the hose type (workpiece) from the two lists: • the nominal width is selected first; • subsequently a coupling matching the nominal width is selected. Confirm the selected tool and continue in the next screen.
  • Page 20 In this screen, the steps for exchanging the crimping dies are shown. For more details regarding the replacement of the crimping dies, please refer to the machine Operation Manual. The quick die change system has to be used to change the crimping dies. The die wrench has to be used to change the crimping dies.

  • Page 21: Verify And Adjust Settings

    Verify and adjust settings Screen: Crimping die diameter Screen: Forming dimension diameter. Screen: Permissible tolerance of forming dimension diameter. Screen: Permissible ovality. Screen: Crimping field length. Screen: Crimping field length tolerance. Direct input of forming dimension via input field possible as an alternative. Display: current position of tool.
  • Page 22 The tool automatically opens after the forming pro- cess. The tool does not automatically open after the form- ing process. Enter additional settings (see following screen). Help (only if available, otherwise logo) Back to selection of product range. Favourites even remain unchanged if the data are reloaded from a USB storage medium.
  • Page 23 Only if automatic opening is active : Upon form- ing, the crimping dies remain on the workpiece until the machine opens them again (holding time). Pre-select the number of workpieces to be pro- cessed. If "0" is entered, a deliberate number of forming processes may be performed without a message appearing.

  • Page 24: Crimp Without Workpiece Table

    Crimp without workpiece table Start screen The following control screen is opened by pressing the manual opera- tion button: Manual operation Semi-automatic operation Machine settings The figures are described in more detail in the Sections below.

  • Page 25: Manual Operation

    Manual operation This screen is activated to specify the settings for a forming process in the “Manual operation” mode. Enter forming dimension diameter. The forming di- mension diameter is the diameter to which the tool is adjusted. If a new forming dimension is entered, the set crimping die diameter is adjusted automatically.
  • Page 26 (Option) Crimping die thickness The symbol with the input field will only be dis- played, if the use of special crimping dies is possi- ble in the machine, and if the selected crimping di- mension exceeds or is equal to the smallest possible special criming die.

  • Page 27: Semi-Automatic Operation

    Semi-automatic operation Form to a diameter. Form to a pressure value (only PFM and PFC). Load data record from database. Read data using a scanner (option). Return to Start screen. When the machine is switched from "Semi-automatic operation" to "Manual operation", •...

  • Page 28: Form To A Diameter

    6.3.1 Form to a diameter Screen: Name of current data record. Touching: Load data record from database. Delete data record from input field. Enter forming dimension diameter. The forming di- mension diameter is the diameter to which the tool is adjusted. If a new forming dimension is entered, the set crimping die diameter is adjusted automatically.
  • Page 29 Adjust the set forming dimension diameter upwards (+) or downwards (-) by 0.1 mm or with a figure value. Direct input via input field possible as an al- ternative. Only if automatic opening is active : Upon form- ing, the crimping dies remain on the workpiece until the machine opens them again (holding time).
  • Page 30 Pre-select the number of workpieces to be pro- cessed. An appropriate message is displayed as soon as the selected number of workpieces is reached. If "0" is entered, a deliberate number of forming processes may be performed without a deactivation of the control.
  • Page 31 Only for HM 220 C and HM 225 C. Switches from slow pressing (tortoise) to rapid pressing (rabbit) and vice-versa. Slow pressing (tortoise) = 100 % pressing force. Quick pressing (rabbit) = 45 % pressing force. The current data record automatically changes over to the next data record (subsequent data record).
  • Page 32 Proceed to the following screens: Settings • Hose operating pressure • Counter See “Operating pressure and counter settings”, Section 4. (Option) PFC only: PID controller settings. See “Pre-set PID controller (PFC only)” in Section (Option) Label printer • Green display: automatic printing activated with every second forming cycle.

  • Page 33: Form To A Pressure Value (Only Pfm And Pfc)

    6.3.2 Form to a pressure value (only PFM and PFC) Screen: Name of current data record. Touching: Load data record from database. Delete data record from input field. Enter forming pressure to be operated by the ma- chine. Enter opening diameter. The current diameter at which the machine is set is accepted as opening diameter.
  • Page 34 Only if automatic opening is active : Upon form- ing, the crimping dies remain on the workpiece until the machine opens them again (holding time). Manual opening during the holding time is possible at any time by pressing the button. Holding time = time interval in which the plastic forming of the material is completed.
  • Page 35 Pre-select the number of workpieces to be pro- cessed. If "0" is entered, a deliberate number of forming processes may be performed without a deactivation of the control. An appropriate message is displayed as soon as the selected number of workpieces is reached. Screen: Number of forming processes completed so far.
  • Page 36 Only for HM 220 and HM 225. Switches from slow pressing (tortoise) to rapid pressing (rabbit) and vice-versa. Slow pressing (tortoise) = 100 % pressing force. Quick pressing (hare) = 45 % pressing force. The current data record automatically changes over to the next data record (subsequent data record).
  • Page 37 Proceed to the following screens: Settings • Hose operating pressure • Counter See “Operating pressure and counter settings”, Section 4. (Option) PFC only: PID controller settings. See “Pre-set PID controller (PFC only)” in Section (Option) Label printer • Green display: automatic printing activated with every second forming cycle.

  • Page 38: Operating Pressure And Counter Settings

    6.3.3 Operating pressure and counter settings Hose nominal pressure input. It is only required to input the value, if the value in- dicated is to be printed on a label (see “UNIFLEX LAGEL SYSTEM ULS” in Section 5). For recording unit quantities, for instance, two va- cant unit counters are available.

  • Page 39: Load Data Record From Database

    6.3.4 Load data record from database. The control panel shows the database as a list of data records includ- ing names and forming data. The requested data record is selected by a touch and is then highlighted grey. Name of data record Forming dimension diameter Forming pressure Crimping die diameter...

  • Page 40: Load Data Record Using A Scanner (Option)

    6.3.5 Load data record using a scanner (option) Scan the barcode using the scanner, or enter the barcode clear text manually. The scanned barcode is interpreted as the name of a data record. By accepting the scanned code, the data record table is searched for the appropriate name.
  • Page 41 The codes processed by the scanner can be taken from the de- scription enclosed to the scanner.

  • Page 42: Control Settings

    Control settings The machine settings area is password protected. After the user has logged in, all screens may be opened one after the other. User log in Enter user name. UNIFLEX default: user Enter password. UNIFLEX default: user Screen: Total number Screen: Software version xx_x.x Screen: Active control panel...

  • Page 43: Data Base

    Data base The control panel shows the database as a list of data records includ- ing names and forming data. The requested data record is selected by a touch and is then highlighted grey. Delete selected data record from database. Confirm the selected data and continue in the next screen.

  • Page 44: Data Management With A Usb Storage Medium

    Data management with a USB storage medium The USB socket is located on the back side of the control console (to be used for storage media certified by UNIFLEX only). Load data from an USB storage medium into the control. Load data from the control onto the USB storage The data upload from USB storage medium was successful.

  • Page 45: Crimping Die Editor

    Return to previous screen. Proceed to next screen. Crimping die editor In this screen, crimping die data records may be adjusted, deleted or entered. List of saved crimping die data records. Add crimping die data record. The new crimping die data record is automatically sorted numerically in the list.

  • Page 46: Operating Interface

    Return to first machine settings screen (database). Proceed to next screen. In the crimping die editor, all crimping die data records of the man- ufacturer are included when the machine is delivered. Operating interface Return to previous screen. Proceed to next screen. Tap the desired user interface in order to select it.

  • Page 47: User Administration

    No or other surfaces may be selected according to the specific lay- out. User administration In this screen, users may be created or deleted; in addition, pass- words or the user level may be modified. User name The user name consists of an alphanumerical string without spaces.
  • Page 48 Shows the user interface assigned to the respective user. Selects the previous user, if any. Selects the next user, if any. Add user. Delete user. Save user data. Return to previous screen. Return to first machine settings screen (database). Proceed to next screen. Creating a user Select “Add user”.
  • Page 49 User names User names and the associated passwords are created or deleted by the operator. The user name currently logged on cannot be deleted. If the current user name is to be deleted, it is necessary to log on an- other user first.

  • Page 50: Language

    Language The currently set language is shown at the top. Select the appropriate language by touching the flag (1). Return to previous screen. Return to first machine settings screen (database). Proceed to next screen.

  • Page 51: Machine Settings

    Machine settings Screen: Machine type Preset zero point and/or reference point of ma- chine. Screen: Permissible range before zero point is reached, as from where the machine may build up force without causing damage to the bearing plates. The dimension depends on the geometry of the tool and cannot be changed.
  • Page 52 Analog digital converter Converts 0 - 400 bar in 0 – 27648 scale marks. The machine motor is switched off after expiry of the period set here. Diameter pre-setting: When a new forming diame- ter is entered, the diameter entered here is auto- matically added to the forming diameter and ac- cepted as switch point.

  • Page 53: Instructions For Action

    The control operating system is started. If the control CONTROL C.2 does not start automatically, double click on Uniflex (4) in order to switch to the CONTROL C.2. The Uniflex logo is shown before the first machine settings screen opens (database).

  • Page 54: Changing The Crimping Dies

    The Windows settings in Regional Settings must not be changed since otherwise the value tables are interpreted incorrectly. Changing the crimping dies In this screen, the steps for exchanging the crimping dies are shown. The quick die change system has to be used to change the crimping dies.

  • Page 55: Check With Calliper (Option)

    Details of how to change the crimping dies can be found in the Op- eration Manual of the respective machine. Check with calliper (Option) The forming result including a freely selectable tolerance range may be checked by using a calliper. For this purpose, measure the work- piece at the point indicated by the triangle.
  • Page 56 Current calliper value. If the message “mm/inch? mm” is displaced, the pre-set unit of the calliper does not comply with the 0021.91 pre-set unit of the machine. Correct the measuring unit of the calliper or the machine. If the message “Error mm” is displayed, no calliper is identified, or the communication between the cal- liper and the control is disrupted.
  • Page 57 Forming dimension diameter (preset dimension). Set correction value of forming dimension diameter. Measuring result of the diameter as the mean value of the individually measured values. Rules: • Green display: the workpiece is within the per- missible tolerance • Red display: the workpiece is not within the permissible tolerance The pre-set tolerance value is indicated behind the symbol.

  • Page 58: Calibration

    Measuring result of the ovality as the mean value of the individually measured values. Rules: • Green display: the workpiece is within the per- missible tolerance • Red display: the workpiece is not within the permissible tolerance • Grey display: the measurements are not suffi- cient (e.g.
  • Page 59 During calibration, the zero point and the crimping tool inclination are set. This is required i.e. if the slide bearing plates have been changed. The "Calibration" screen is found in the machine settings and is password protected. The process is shown in this screen and the next screen: Select the UNIFLEX calibration mandrel with the in- dicated number.
  • Page 60 Remove calibration mandrel: • Hold calibration mandrel and • Open tool with button. Calibration was successful. Calibration was not successful, repeat calibration process. Accept calibration and return to first machine set- tings screen (database). The machine may also be calibrated by directly entering the zero point.

  • Page 61: Error Messages

    Error messages Error message “Oil filter contaminated” If an oil filter is used in the machine (depends on the machine type) and this filter is contaminated, an error message is displayed. Replace oil filter in accordance with the instructions given in the Operation Manual of the machine.

  • Page 62: Backup And Restore Control C.2

    Backup and restore CONTROL C.2 In the machine settings (password-protected area), you can switch to the operating system via the To the operating system button. Backup CONTROL C.2 Start StartCenter (6) by a double click. The screen "Transfer" is opened, and the transfer is started.
  • Page 63 14. Remove USB storage medium. 15. Restart the machine control by switching it off and on again at the main switch. Restore CONTROL C.2 Start StartCenter (6) by a double click. The screen "Transfer" is opened, and the transfer is started.
  • Page 64 14. Remove USB storage medium. 15. Confirm the message Restore operation successfully completed with OK. 16. The machine control is restarted automatically and is then ready for operation again.

  • Page 65: Annex

    10 Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders. 10.1 Accessories (retrofittable) Accessories Part code Double foot switch PS.2 Double Calliper including cable and foot sensor Calliper CtrlC 3 Inch Calliper including cable and foot sensor Calliper CtrlC 4 Inch...

  • Page 66: Spare Parts List

    Only use original ULS coloured tape. Please contact our Sales department for ordering accessories. 10.2 Spare parts list Version 807.600 Position Number Article number Designation 807.710 Control panel 800 mm C.2 with memory card 807.374 Uniflex Touch Panel 807.066 Emergency stop unit 800.061 “Motor Start”...
  • Page 67 Version 807.700 Position Number Article number Designation 807.710 Control panel 800 mm C.2 with memory card 807.374 Uniflex Touch Panel Emergency-stop button, complete, as from ap- 807.067 prox. 10/2016 (date of production) 800.061 “Motor Start” button 800.060 “Motor Stop” button 807.068 Button: Foot pedal switching 800.063...

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