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Summary of Contents for KODERA CASTUGNON C551HXG
- Page 1 Operation Manual Ver.5 Important: Please read this operation manual carefully before using CASTUGNON C551HXG. Please observe the safety precautions to operate this device safely. Please keep this manual at hand so that you can read it whenever necessary.
- Page 2 Safety Precautions If you do not operate the device properly, it may result in failure or accident. Please read this operation manual carefully before operating the device. Danger: If you do not observe this item properly, it may result in death or severe injury. Caution: If you do not observe this item properly, it may result in moderate disorder, slightly injury or material damage.
- Page 3 Caution: If abnormal smell (burnt smell) is detected, stop the operation and turn the device off. ➡Contact the sales distributor. Caution: Do not stand or put an object on the device. ➡It may cause injury due to drop or fall over. Caution: Before cleaning, maintenance or inspection, make sure to remove the power cable and check that the device is not energized.
- Page 4 Precautions for Installation Caution: Install the device where it can support the weight and level. ➡If not properly installed, the device may fall and cause injury, vibration or operation noise. Caution: Ground the device. Do not connects the ground wire to the ground wire of gas or water pipe, lightning rod or telephone.
- Page 5 Layout of Ｃ551HXG Front Crimper Conveyor Front Crimper Front Terminal Feeder 1 MEKA Rear Terminal Feeder Wire run-out Sensor Roller Rear Paper Winder Rear Terminal Reel Straightener Operation Panel Front Applicator Upper 2 Meka （Cutter Meka） Guide Pipe Front Applicator Lower Front Terminal Feeder ４...
- Page 6 Rear Applicator Upper Cutter Block C Chuck Grip （Rear Strip） Rear Applicator Lower E Meka D Chuck （C to E） E Chuck （Discharge） Conveyor Belt Wire tray ５...
- Page 7 Contents Safety Precautions ....................１ Handling Instructions ..................１ Precautions for Installation ................３ １）Before Operation ....................７ ２）How to Turn On/Off the Power ................８ ３）Description of Setting Screen ................９ [Basics] ....................... ９ [Others] ......................１１ [Front Crimp-Waveform] ................１３ [Front Crimp-Setting] ..................
- Page 8 １）Before Operation Coupler with Air Valve Connection of Power Cable ① Make sure that the power switch of operation panel is off. Insert the attached power plug innermost to the power inlet. The power inlet is located at the power box which is at the bottom on the side of the main body. Check the indicated power supply voltage carefully.
- Page 9 ２）How to Turn On/Off the Power ①How to Turn On/Off the Power (Normal) Use [Power Switch] on the operation panel to turn ON/OFF. Turn the [Power switch] to the [1] side to turn on the power supply, and turn the power off if you tilt it to the [0] side.
- Page 10 ３）Description of Setting Screen This section explains the items on each screen of C551HXG. It has a touch type display operation screen. Please touch the touch panel with a soft thing such as a fingertip. And do not operate with the sharp pointed object. It may result in failure [Basics]…Set the dimensions and the number of wires etc.
- Page 11 ⑭、⑮ Input with the size of the wire When applicator was set, Wire data in the applicator is read automatically. The numerical values of ⑪, ⑫, ⑭, ⑮ are entered automatically by referring to the following table according to the entered value. (JIS)sq.(㎟) Core Corrector...
- Page 12 [Others]… Set the <speed of the length measurement>, <language selection> and so on. ① 《Language Selection》：To select the language to display on the operation panel. ② 《Feed speed》：To select the speed of the length measuring. Length measuring speed is the fastest. 《Standard》...
- Page 13 When 《Z》mode is used：When Z mode is turned on,《Guide pipe set range》 is indicated. Please set [protruding margin amount of Guide pipe] the after crimping. ➡Check the protrusion amount of the terminal by <step by step mode> and set it. (Example: Over 13mm in case of SVH-21T-P1.1) The location of the tab Wire》：Use this function to process the wire which is very soft, delicate and not firm.
- Page 14 [Front Crimp-Waveform]… This is the screen to confirm the 《Standard Pressure》, 《Pressure Waveform》and 《tolerance of crimping》. ①《Standard Pressure》：It is the numerical value of the maximum pressure when waveform was decided. ②《Maximum Pressure》：It is a pressure value of the peak of the pressure waveform being displayed now.
- Page 15 [Front Crimp-Setting] ・・・This is the screen to set up the crimping position of front end, crimp height and tolerance of crimping. ①Set the range of green lines (②, ③) in the above figure. ➡It can be set from 0(the extreme left of the horizontal axis) to 511(the extreme right of the horizontal axis) and detects errors only within the set range.
- Page 16 Area A Area B In the above figure, the Start of《area A》is 330, the end of《area A》,the start of《area B》is 400, and the end of《area B》is 470. In this setting, the upper limit of the reference pressure is allowed to be 10% in the 《 area A》 (330~400), and the pressure difference up to 8% is allowed in the bottom limit.
- Page 17 [Front Crimp-Information]・・・Various information on front crimp can be confirmed. (Impossible to make a correction on this screen) ①Display the model number the upper side of the front applicator. Display terminal manufacturer name used with front applicator.（Abbreviate to three character） ② ③Display the part number of the terminal used with the front applicator.
- Page 18 [Rear Crimp-Waveform]… This is the screen to confirm the 《Standard Pressure》, 《Pressure Wave》and 《tolerance of crimping》. ①《Standard Pressure》：It is the numerical value of the maximum pressure when waveform was decided. ②《Maximum Pressure》：It is a pressure value of the peak of the pressure waveform being displayed now.
- Page 19 [Rear Crimp- Setting] ・・・This is the screen to set up the crimping position of rear end, crimp height and tolerance of crimping. ①Set the range of green lines (②, ③) in the above figure. ➡It can be set from 0(the extreme left of the horizontal axis) to 511(the extreme right of the horizontal axis) and detects errors only within the set range.
- Page 20 Area A Area B In the above figure, the Start of《area A》is 240, the end of《area A》,the start of《area B》is 380, and the end of《area B》is 460. In this setting, the upper limit of the reference pressure is allowed to be 10% in the 《 area A》 (240~380), and the pressure difference up to 8% is allowed in the bottom limit.
- Page 21 [Rear Crimp-Information] ・・・Various information on front crimp can be confirmed. (Impossible to make a correction on this screen) ①Display the model number the upper side of the rear applicator. Display terminal manufacturer name used with rear applicator.（Abbreviate to three character） ②...
- Page 22 [Machine Adjustment]… This is the screen to adjust the origin of the machine. (In principal do not change the origin of the machine) ①《Guide pipe origin》：The origin of the guide pipe ➡[+]：Keep away from the blade [-]：Approaching the blade ②《Blade origin》(2 MEKA)：Origin point of the cutter ➡[+]：Blade opens [-]：Blade closes origin》：Origin of C chuck (rear end movement)
- Page 23 ⑨《Time before feed wire》：Additional time just before the measurement starts（unit：sec） ➡Usually, use [0 seconds]. ※The right-side value is automatically adjusted by the machine which determines the value based on the conditions for the wire and the terminal. length》：Setting the length when trimming the electric wire（unit：mm）...
- Page 24 [Test Mode]…Each operation signal can be tested. ※MGM = Main Board, MGC = Crimper Board Main ①《Chip blow air》：MGM's LED26 lights up, and you can test ON / OFF of solenoids of blow away insulation slugs. ②《C-chuck》：MGM's LED27 lights up, and you can test ON / OFF of the C chuck opening and closing solenoid.
- Page 25 Crimper1 ⑭《Terminal feed nail》：You can test ON / OFF of <Terminal feed nail> solenoid. ⑮《Carrier cut》：You can test ON / OFF of carrier cut solenoid. ⑯《Crimp completion signal》：MGM's LED 44 lights up. ⑰《Crimp judgment signal》：MGM's LED 45 lights up. ⑱《C to D》：MGM's LED 66 lights up. Crimper2 ⑲《Terminal feed nail》：You can test ON / OFF of <Terminal feed nail>...
- Page 26 ４）Applicator An applicator exclusive to the HX series is required for this machine. The applicator stores data such as terminal part number, crimp height, crimp force, strip length, crimping position, blade value, number of shots, etc. Applicator Upper Applicator Lower How to Attach the Applicator ①...
- Page 27 ① ：The beep sound is heard, the terminal part number is displayed on the operation panel, and the terminal part number stored in the ID tag built in the applicator is displayed. ※If there is a problem with the set applicator, it will be displayed as shown below. ・Please check that the applicator is in ・Please check the wire type registered the correct combination on the top and...
- Page 28 ５）Setting of Terminals Terminal Reel Rotation Direction Switch Reel Shaft Stopper In case of “the Counter winded terminals” or “A small amount of winded terminals”, loosen the two parts of the terminal reel fixing screws and pull out the terminal reel forward and use it.
- Page 29 Setting of Terminals Fixed Lever ① ：Take stopper out. ② ：Set the terminal reel on the reel shaft. Fix the terminal reel using the pin of the terminal guide plate side. ③ ： Fasten the terminal reel with the stopper. Terminal Holder ④...
- Page 30 Terminal Guide ⑧ ：Pass the terminal through the terminal guide. ⑨ ：Pass the carrier the lower applicator to near the red line in the above figure. After passing through, pull the carrier a little and hook it on the <terminal feed nail>. About Terminal Holder, As standard, four springs are built inside the terminal holder.
- Page 31 ⑩：After setting both the front and rear to <procedure ⑨>, press the [Process Start] button. The screen is switched to shown below. ⑪：Press <Feed terminal on front> and <Feed terminal on rear> circled in red line in the above figure, The terminal feeder moves by 1 pitch. Press each button until the terminals come to each crimp position.
- Page 32 ６）Setting of Wires ①：Guide Pipe The appropriate inner diameter size for guide pipe is that the wire goes into the guide pipe exactly and goes through without any frictions. However, such as strong wire curl tendency etc., it is necessary to replace the guide pipe to adjust to the curl tendency.
- Page 33 ７）Settings On the [Basic] screen, set the processing conditions. ①：By installing the applicator, "Core diameter", "Blade move back", "Crimp position", "Strip length" are read and input automatically in the applicator. If you have processed by the same applicator before, the last determined data will be read out ②：Next, set [Total length].
- Page 34 ８）Pre-Volume Production Processing Before volume production, sample processing is necessary to decide waveform of crimping etc. ① ：On the [Basic] screen, when all settings are completed, press the [Process start] button at the lower right of the screen. The screen is switched to shown below. ②...
- Page 35 If adjustment is necessary, Set the value of [Crimp position] to "+", "-". Unit：0.1mm Set the value of [Stripping length] to "+", "-". Unit：0.1mm Set the value of [Crimp height] to "+", "-". Unit：0.001mm Set the value of [Terminal feed correction] to "+", "-". Unit：0.1mm When adjustment is completed on the control panel as shown above, press the [Setting] button to return to the [Basic] screen, return to step ①...
- Page 36 ９）Volume Production Processing ① ：Set the [Total length] and [setting pieces]. ② ：Touch the [Current pieces] and input [0], [SET] by numeric keypad. After completion of 1, 2, start volume processing ③：Press the [Process start] button on the right side of the [Basic] screen. (Red line in the above figure) ④：If you press the [Production Mode] button, volume processing starts.
- Page 37 １０）How to Adjust the Air Pressure Open the door on the front side, there is an air regulator. Regulator A：Adjust the air pressure of the entire machine. Pull up and turn the lock volume. Please use at 0.5 ～ 0.6 MPa. B：This is the adjustment of air when it fly chips away at stripping.
- Page 38 １１）Crimp Force Monitor This machine monitors the pressure applied (crimp force) to each terminal during terminal crimping by the pressure sensor incorporated in the crimper. Defective products such as <Crimping without core wire>, <with broken core wire>, <with broken outer cover>, etc. show different pressure waveforms from the ordinary products. This difference is applied to judge the error.
- Page 39 ⑤：Influence on pressure due to temperature change of crimping machine Example） After you processed for two to three hours continuously and stopped the device for 30 minutes, when you resume operation with the same processing condition, you may experience a slight change to the pressure and result in an error.
- Page 40 １２）How to Replace Parts Make sure to turn off the machine when you replace the parts. 1：How to Replace the Roller How to remove the roller ：Remove the screw the side of the ① rollers.（There are screws on both the left and right side, remove a screw on only one side(left or right)）※There is the roller pressure...
- Page 41 2：How to replace guide pipe and entrance guide How to remove the guide pipe Loosen the screws indicated by the red circles on the left figure and pull them up. ※Be careful not to lose and drop the screws. How to attach the guide pipe Place it so that the groove indicated by the arrow in the left figure overlaps the location of the...
- Page 42 3：How to Replace the Stripping Blade and Cutting Blade Please be careful about handling of a blade sufficiently. ①：Remove the air hose of 2 MEKA indicated by the red circl in the left figure. (When pressing the black ring of the one-touch joint, the air hose can be pulled out.) ②：Remove two + screws indicated by the red circles in the figure below.
- Page 43 ③：Remove the screw indicated by the red circle on the left figure and disassemble the <Cut-Unit top cover> and <upper cutter block>. Pull out the blade. ④：Loosen the red circled screws in the left figure and pull out the blade. Please remove the garbage etc.
- Page 44 ⑥：Press the blade against the flat surface as shown on the left and tighten the screw so that the end faces are aligned neatly. Put back the cut-unit top cover. Flat surface If the screw is tightened too much, it may break. Be careful not to over tighten the screws.
- Page 45 Stripping Blade ⑧：Place the side of the black screw in front. From the right ・The engraved side of the strip blade faces leftward ・ The engraved side of the cutting blade faces leftward ・The engraved side of the strip blade faces rightward Place each blade in the order shown above.
- Page 46 4：How to change the Crimper ①：Loosen two nuts indicated by the red circles on the left figure. ②Take out the wire crimper and insulation crimper. caution：Make sure there is a spacer between wire crimper and insulation crimper. Spacers ③：Set new wire crimper and new insulation crimper. If you check the spacer on ②, set the spacer between wire crimper and insulation crimper.
- Page 47 5：How to change the Anvil ①：Remove the screw indicated by the red circle line in the left figure, and remove the wire anvil and the insulation anvil. Insulation Anvil Wire Anvil One streak indicated by the arrow in the above figure is an insulation anvil, and two streaks are a wire anvil.
- Page 48 １３）Dust Box Terminal carrier dust： Cut it regularly at the set length (Refer to P.21 machine adjustment screen) from the carrier discharge duct and fall into the trash can. ※ The length of cut varies changing on the pitch of the terminals.
- Page 49 １４）Consumable Supplies List Product Name Order Number Remarks Guide pipe A φ1.0 551HX-501-1.0 Guide pipe A φ1.5 551HX-501-1.5 Guide pipe A φ2.0 551HX-501-2.0 Guide pipe A φ3.0 551HX-501-3.0 Guide pipe B φ1.0 551HX-502-1.0 Guide pipe B φ1.5 551HX-502-1.5 Guide pipe B φ2.0 551HX-502-2.0 Guide pipe B φ3.0 551HX-502-3.0...
- Page 50 １５）The installment of the MDU board Open the door on the rear end side of the main body, there are MDU boards. (Refer to the picture) Be sure to drop the breaker of this machine when replacing the MDU boards. Also, even after turning off the power, voltage remains for several minutes, please be sure to wait over 5 minutes before replacing.
- Page 51 １６）Expansion Plan of Applicator Applicator Upper Type1 Applicator lower Type6 ５０...
- Page 52 １７）Daily Check and Maintenance To use it for a long time and to prevent the occurrence of defective products beforehand, periodic inspection and maintenance are indispensable. It also depends on use frequency, but consults the next table, and please takes care of implementation. Daily inspection and maintenance Wear and chipping of cutting blade Symptom...
- Page 53 Specification ◆Model, Function CASTUGNON C551 HXG Model (Includes crimp force monitor as a standard equipment) Both ends stripping, both ends terminal crimping Function ◆Processing dimension Maximum setting Front/Rear end 0.1mm ～ 7.0mm value for stripping Minimum process- able dimension L= 62mm + Distance to the insulation barrel of the front side The above dimension varies according to the wire rod and Type of terminals.
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