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Continental Refrigerator PC200i Operator's Manual

Crimper with crimpiq controller
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PC200i Crimper
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Operator Manual
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  • Page 1 Group or Division Here Industrial Fluid Solutions PC200i Crimper with CrimpIQ™ Controller Operator Manual www.contitech.us www.contitech.us...

  • Page 2: Table Of Contents

    PC200i Crimper – Operator Manual Table of Contents PC200i Safety Precautions ..............................................................4 PC200i Initial Crimper Setup ..............................................................5 High-Level CrimpIQ™ Controller Capabilities....................................................6 CrimpIQ™ supports the following features ....................................................6 PC200i Series ......................................................................7 PC200i Features ....................................................................8 Initial Crimper Setup ..................................................................9 Overview ......................................................................9 Crimper Operations ..................................................................10 Logging In ....................................................................10...
  • Page 3 Configuring CrimpIQ™ Calipers (USB) .....................................................48 Setting Up USB Calipers ............................................................48 Using CrimpIQ™ Calipers............................................................49 PC200i Lubrication Procedure ............................................................50 PC200i Die Installation and Management ......................................................51 Adapter Die Installation ..............................................................51 Hydraulic Die Installation ............................................................52 PC200i Manual Back Stop Setup ..........................................................53 PC200i PLC Reset Procedure ............................................................54 Resetting the PLC to Its Original Settings ...................................................54...

  • Page 4: Pc200I Safety Precautions

    SAFETY PRECAUTIONS • Read instructions and identify all component parts before using the crimper. • PC200i crimper can produce 340 tons of crimping force. • Keep both hands away from pinch points. • Consult the Continental Crimp Specifications Manual for correct crimper setting and crimp measurements.

  • Page 5: Pc200I Initial Crimper Setup

    Notes: • Plug the PC200i crimper directly into the appropriate electrical circuit/wall outlet. • Electrical Requirements: 7.5HP/230V/3Phase (20 Amp) 7.5HP/440V/3Phase (20 Amp) 5HP/230V/1Phase (30 Amp)

  • Page 6: High-Level Crimpiq™ Controller Capabilities

    PC200i Crimper – Operator Manual High-Level CrimpIQ™ Controller Capabilities This version of the CrimpIQ™ controller is designed to take full advantage of the tablet interface and the connection to CrimpCloud®. CrimpCloud® is a web portal that provides users access to crimping and quality results captured in the CrimpIQ™...

  • Page 7: Pc200I Series

    PC200i Crimper – Operator Manual PC200i Series Crimping Head CrimpIQ™ Controller Notch For Clearance Motor Of 90° Fittings 10-inch Color Touch Screen Manual Back Stop Emergency Stop Audio and USB Ports Pressure Compensation Crimper Head Open Button Oil Filler Cap...

  • Page 8: Pc200I Features

    PC200i Crimper – Operator Manual PC200i Features Continental CrimpIQ™ controller, the 10-inch color capacitive touchscreen Intuitive screens lead the operator future of crimping at your fingertips. and user- friendly navigation. through the setup and crimping process. Quickly Interchangeable Adapter Dies.

  • Page 9: Initial Crimper Setup

    PC200i Crimper – Operator Manual Initial Crimper Setup Overview Before the crimper can be used for the first time, a brief setup process must be completed. This process sets some initial parameters, identifies this machine to the CrimpCloud® system and allows the user to confirm the Terms and Condi- tions for use of this machine.

  • Page 10: Crimper Operations

    PC200i Crimper – Operator Manual Crimper Operations Logging In To begin using the crimper, you must first login. The crimper supports multiple users to allow tracking of activities as well as restrict access to some configuration type functions. Default User Accounts The system comes with 3 users already created: admin, machine owner and user.

  • Page 11: Navigating The Crimpiq™ Controller

    PC200i Crimper – Operator Manual Navigating the CrimpIQ™ Controller This section provides an introduction to the controller screens and functions that are common throughout the application. Basic Application Guide This section outlines basic functions within the app that are common throughout the application. The basic outline and functionality is common throughout the application.

  • Page 12: Left Slide-Out Menu Functions

    PC200i Crimper – Operator Manual Left Slide-Out Menu The left slide-out menu is available from anywhere within the Crimp controller app. It can be accessed by pressing the Menu but- ton (always on the lower left side) or by swiping left from the left side of the screen.

  • Page 13: Using The Main Menu

    PC200i Crimper – Operator Manual Using the Main Menu This screen provides the main functions of the crimper. CrimpIQ™ Controller Main Menu Screen Options Begin Crimping: This button brings up the functions to perform hydraulic and industrial hose crimping. Favorites: The Favorites button provides users with direct access to favorited crimp specifications.

  • Page 14: Crimper Operations

    PC200i Crimper – Operator Manual Crimper Operations Main Crimper Operations Screen The crimper operations screen is the starting point for setting up a crimping operation. Favorites: This function contains all of the crimp specifications that have been previously favorited. Crimp to Diameter: This function allows the user to directly enter a crimp diameter.

  • Page 15: Mycrimp® - Search Screen

    PC200i Crimper – Operator Manual MyCrimp® – Search Screen Use the Hose Type, Coupling Type and Hose Size to find the crimp specifications you need. Key Functions of MyCrimp® Hose Type: Drill down into a list of hose types. Coupling Type: Drill down into a list of coupling types.

  • Page 16: Mycrimp® - Results Screen

    PC200i Crimper – Operator Manual Once you find the desired crimp specification, View Crimp Specifications will allow users to review the match- ing crimp specifications. MyCrimp® – Results Screen This view provides a review of the hose and fitting selected. Select “Begin Crimping” to begin crimping.

  • Page 17: Mycrimp® - Crimp This Specification

    PC200i Crimper – Operator Manual From the detailed view, users can view the full details of the crimp specifications. Users can return to the previous screen with the Back button in the upper left corner or by using the "More Options" menu in the upper right to “Export Specification.”...

  • Page 18: Crimp Specifications With Special Handling Requirements

    PC200i Crimper – Operator Manual Crimp Specifications with Special Handling Requirements There are cases where the user has to perform additional steps in order to select the correct crimp specification for the hose and fitting combination. In these cases, MyCrimp® will prompt the user with additional information. Users can then take the appropriate actions.

  • Page 19: Favoriting Crimp Specifications

    PC200i Crimper – Operator Manual Favoriting Crimp Specifications The user can save frequently crimped specifications for easy access and repeated crimping. This brings up a list of all the favorites saved on this machine. This scrollable list can be sorted by date added (Recent), Favorite name (Name) or hose size.

  • Page 20: Editing A Favorite

    PC200i Crimper – Operator Manual Editing a Favorite Users have the option to edit the Favorite name and notes. You also have the option to delete favorites that are no longer needed. Favorite Special Handling There are a subset of crimp specifications that require special handling. For these favorites, users must make an additional check to verify that the correct crimp specification has been selected.

  • Page 21: Crimp To Diameter

    PC200i Crimper – Operator Manual Crimp to Diameter If you already have the crimp specification information, you can enter this directly and begin crimping. Simply choose the Crimp to Diameter option from the Crimper Operations page. Enter the appropriate crimp diameter target (in inches or mm). As you enter a target diameter, the crimp automatically calculates the equivalent measurement in the other unit of measure.

  • Page 22: Mycrimp® Industrial

    PC200i Crimper – Operator Manual MyCrimp® Industrial Crimp Calculator The Industrial Crimp Calculator allows users to enter information about the industrial hose, stem and sleeve, along with a compression ratio. The calculator will then calculate the appropriate crimp diameter. The calculator provides additional details on each required value. Press on the measurement icon and a more detailed description pops up.
  • Page 23 PC200i Crimper – Operator Manual Sleeve Thickness: The thickness of the sleeve. Compression Ratio: Compression ratios are available from hose and fitting manufacturers. Ratios must be between 10% and 35%. As data is entered, the calculator will determine the final crimp diameter (users cannot proceed to crimping until all fields have information entered).

  • Page 24: Beginning A Crimp

    PC200i Crimper – Operator Manual Beginning a Crimp Loading Dies Regardless of how the crimp specification/crimper was set up, the first step in crimping is to load the correct die into the crimper. As part of the crimper configuration, the dies available to this crimper have been configured (see Managing Preset Dies on page 37).

  • Page 25: Selecting A Die

    PC200i Crimper – Operator Manual Selecting a Die If a non-recommended die or no die is set, the controller will prompt the user with a list of configured dies. The CrimpIQ™ controller will recommend a die that can crimp the required crimp diameter.

  • Page 26: Change Die Mode

    PC200i Crimper – Operator Manual Change Die Mode When you select the die, the pump will start and the Open/Close buttons will work to allow you to load the die in the crimper. Once the die has been loaded, press the OK to continue.

  • Page 27: Crimp Operations

    PC200i Crimper – Operator Manual Crimp Operations Performing the First Crimp The first crimp always needs to be measured to ensure the crimp is within tolerance of the crimp diameter. Note: Once the calibration crimp has been completed and an initial crimp diameter entered (manually entered or entered via USB CrimpIQ™...

  • Page 28: Measuring A Crimp

    PC200i Crimper – Operator Manual Measuring a Crimp The crimper will always prompt the user to measure the first crimp. The crimper uses this measurement to adjust the crimper to correctly crimp the next crimps. When prompted, enter the measured crimp diameter. Measurements can be entered in inches or mm (the cursor will be placed in either field based on the preferred units of measure setup in the machine configuration).

  • Page 29: Crimp Operations Screen

    PC200i Crimper – Operator Manual Crimp Operations Screen This screen provides the main controls for operating the crimper. While on this screen, the pump is running and the Open/Close buttons are enabled (limited by Crimp Mode). Crimp Operations Screen Sections The operations screen is divided into 5 sections: Operations Information, Crimp Detail Panel, Crimp Mode, Crimp Settings and Crimp Management.

  • Page 30: Operational Information

    PC200i Crimper – Operator Manual Operational Information Die Name: The name of the die that is currently installed in the machine. Target Diameter: The diameter the machine is set to crimp to. Current Position: Current die opening in inches and millimeters.
  • Page 31 PC200i Crimper – Operator Manual Crimp Spec: Hose, fitting and hose size information when loading a MyCrimp® specification. Hose Image: If a hose image is available, this image will be displayed. Spec Notes: This view shows the crimp specifications notes.

  • Page 32: Crimp Mode

    PC200i Crimper – Operator Manual Crimp Mode The crimper can operate in any of 3 different modes: Manual Mode: Use this mode to manually Open/Close the head. Holding the Close button will close the head to the target position and no further.

  • Page 33: Crimp Information

    PC200i Crimper – Operator Manual Crimp Information The Crimp Settings section contains status information and also a number of configurable settings that the user can change to adjust the crimp run. Note: Each of these information areas can be configured by pressing the icon to the left of the information.

  • Page 34: Crimp Management Function Buttons

    PC200i Crimper – Operator Manual Crimp Management Function Buttons This section provides buttons to configure and operate the crimper. Measure/Adjust Crimp: This button allows the user to measure and record the crimp diameter. When activated, the user can enter a crimp diameter measurement.

  • Page 35: Settings And Support

    PC200i Crimper – Operator Manual Settings and Support In addition to the basic crimping operations, the CrimpIQ™ controller offers a number of other capabilities. These include: Machine Configuration: Crimp setup/configuration page with all of the configurable options of this device.

  • Page 36: Machine Configuration

    PC200i Crimper – Operator Manual Machine Configuration The CrimpIQ™ controller has a number of configuration options that allow the machine operation to be customized to meet the needs of each installation. Main configuration functions are grouped into menu options at the top of the page. The rest of the configuration screen provides access to all the remaining configuration settings.

  • Page 37: Managing Preset Dies

    PC200i Crimper – Operator Manual Managing Preset Dies This screen provides a list of all of available dies for this crimper. Administrators can set each die to Not Purchased/Purchased to allow the CrimpIQ™ controller to filter the list of dies the user sees to only dies that are available with this machine.

  • Page 38: Managing Users

    PC200i Crimper – Operator Manual Managing Users The crimper comes configured with three user accounts but Administrators have the option to setup additional users. Additional users can be useful to track what each user/admin is doing on the machine. Information on the default users is available in the Key User Information.

  • Page 39: Maintenance Mode

    PC200i Crimper – Operator Manual Maintenance Mode This machine keeps track of a number of different periodic maintenance tasks. Tasks are based on machine model. Maintenance tasks are either triggered by the number of crimps or the number of days since the last maintenance.

  • Page 40: Using A Wi-Fi Connection

    PC200i Crimper – Operator Manual Using a Wi-Fi Connection Initiating the Wi-Fi setup process brings the user to the standard Android Wi-Fi setup screens. Choose the appropriate Wi-Fi Network, enter in any required credentials and connect. When the connection has been established, use the return arrow to return to the CrimpIQ™ controller application.

  • Page 41: Testing Proper Connectivity

    PC200i Crimper – Operator Manual Testing Proper Connectivity You can use the “Verify Connection” button to verify that the crimper can reach the Internet. Users should see the ContiFluidSolutions home page. If you don’t see this page, please contact your network administrator to enable access from the CrimpIQ™...

  • Page 42: Backup To Crimpcloud

    PC200i Crimper – Operator Manual Backup to CrimpCloud® CrimpCloud® has the ability to provide reports on crimper operation and maintenance. In addition, it stores the configuration of the CrimpIQ™ controller (users, dies, favorites). Saving this configuration allows Continental to replace the controller tablet, pre-loaded, with all the backed up configuration.
  • Page 43 PC200i Crimper – Operator Manual Check Internet This feature is used to verify the Internet connection. A green check mark indicates a successful network connection via Ethernet or Wi-Fi. A red exclamation point (!) indicates there is no network connection. There are circumstances where the Wi-Fi signal is present but the tablet still cannot access the Internet.
  • Page 44 PC200i Crimper – Operator Manual Require Measurement On/Off setting for measurement popup on the initial crimp. Continental recommends After 1st Crimp: that users ALWAYS measure the initial hydraulic crimp to ensure that the crimp target is being reached (within tolerance). Turning this setting on always causes the crimper to trigger the measurement popup on the initial crimp.

  • Page 45: Support

    PC200i Crimper – Operator Manual Support The application provides the user with a Technical Support system. This system allows the user to create a support ticket from within the app. The support ticket and machine status information are automatically uploaded to the Continental support staff.

  • Page 46: Create A Ticket

    PC200i Crimper – Operator Manual Create a Ticket To create a ticket, follow these steps: 1) Enter your email address: It is very important that this is entered correctly to ensure the support team can quickly respond directly to the person having the issue.

  • Page 47: Conti Fluid Solutions

    PC200i Crimper – Operator Manual Conti Fluid Solutions This option provides users with access to the Conti Fluid Solutions distributor site which includes tools, literature and services. Training Manuals The controller provides access to a number of different training manuals.

  • Page 48: Other Topics

    PC200i Crimper – Operator Manual Other Topics Integrated Caliper Measurements The CrimpIQ™ controller supports direct integration of measurements (Crimp Diameter). This integration saves time and reduces the chance that measurements are incorrectly en- tered. Configuring CrimpIQ™ Calipers (Bluetooth) The CrimpIQ™ controller supports Bluetooth calipers to input crimp diameter measurements.

  • Page 49: Using Crimpiq™ Calipers

    PC200i Crimper – Operator Manual Using CrimpIQ™ Calipers Once the calipers are connected to the controller, they can be used to enter measurements within the CrimpIQ™ controller screens. • The calipers are now ready to use. Whenever a measurement is required (Measure/Adjust Crimp in Crimper Operations screen), the caliper’s measurement can be directly entered into the text box.

  • Page 50: Pc200I Lubrication Procedure

    PC200i Crimper – Operator Manual PC200i Lubrication Procedure Notes: • Use the mini grease gun with flush fitting adapter with grease (supplied with the crimper) as shown in photo #1 or a high-pressure moly grade grease can be used as well.

  • Page 51: Pc200I Die Installation And Management

    PC200i Crimper – Operator Manual PC200i Die Installation and Management PC200i Die Installation and Management Adapter Die Installation Notes: • The 130 mm O.D. to 99 mm I.D. Adapter Die fingers are held in place by the die locking pins (as shown in photo #1).

  • Page 52: Hydraulic Die Installation

    PC200i Crimper – Operator Manual Hydraulic Die Installation Notes: • With the 130 mm O.D. to 99 mm I.D. Adapter Dies installed, use the Quick Change Tool to install the hydraulic die set. • The I.D. of the adapter dies must match the O.D. of the corresponding hydraulic die set or accurate crimps cannot be made.

  • Page 53: Pc200I Manual Back Stop Setup

    PC200i Crimper – Operator Manual PC200i Manual Back Stop Setup Coupling Stop The Manual Back Stop eliminates guesswork allowing the operator Coupling Stop to visually observe exactly where the crimp will be positioned on the Clamp fitting without the need for trial and error and product scrap due to poor crimp positioning.

  • Page 54: Pc200I Plc Reset Procedure

    PC200i Crimper – Operator Manual PC200i PLC Reset Procedure Motor Relay Dies Open Relay Dies Close Relay The PLC (Programmable Logic Controller) requires a relatively constant source of electrical power. Power surges, outages or drops in power can cause the PLC to lose its settings. This may result in missing or misplaced information on the controller screen.

  • Page 55: Pc200I Troubleshooting

    PC200i Crimper – Operator Manual PC200i Troubleshooting PROBLEM: THE CRIMPER WILL NOT RUN AT ALL: • Check the E-Stop switch to be certain that is not depressed. A slight twist is required to release switch after it has been depressed.

  • Page 56: Pc200I Component Parts Breakdown

    PC200i Crimper – Operator Manual PC200i Component Parts Breakdown 40 41 DETAIL A 22 23 34 35 PC200i Component Parts Breakdown PC200i Crimper with CrimpIQ™ Controller...
  • Page 57 PC200i Crimper – Operator Manual PC200i Component Parts Breakdown Crimper Assembly - IC240 (CC38) / IC340 (CC4-50) / IC260 (CC60) Crimper Assembly PC200i / PC400i ITEM PART NUMBER DESCRIPTION 102618-WELD CC Crimper Reservoir 103049 Sight Glass 4534K43 3/8-18 NPTF Hex Socket Pipe Plug...
  • Page 58 PC200i Crimper – Operator Manual PC200i Component Parts Breakdown Motor and Pump Assembly CC Motor and Pump Assembly (101714) ITEM PART NUMBER DESCRIPTION 101541 5 HP 1800 RPM Motor 101540 7.5 HP 1800 RPM Motor 102994 10 HP 1800 RPM Motor...
  • Page 59 PC200i Crimper – Operator Manual PC200i Component Parts Breakdown OPTIONAL Crimper Table Assembly (101755) Description Item Part Number 101244 Die Panel 101246 End Panel 90108A030 5/16 Flat Washer 91102A030 5/16 Lock Washer 92865A581 5/16-18 X 1 Hex Bolt 95462A030 5/16-18 Hex Nut...

  • Page 60: Pc200I Warranty

    PC200i Crimper – Operator Manual PC200i Warranty Should you experience difficulty with any product or part and require technical support, first contact Customer Service at 1-800-235-4625. This Continental branded crimper is manufactured especially for ContiTech and is covered by the manufacturer under the below warranty.
  • Page 61 Industrial Fluid Solutions ContiTech. Smart Solutions Beyond Rubber The ContiTech division of the Continental Corporation Market segment is one of the world’s leading industry specialists. As Hydraulic Hose a technology partner, our name is synonymous with Contact expertise in development and materials for components ContiTech made of natural rubber and plastics and also in 703 S.

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