Bacc36en PDF

CrimpCenter 36 S
Base Machine
Original Manual
Edition 1.4 (08-2015)
| | CrimpCenter 36 S
1 | 212
Address / distributors
Schleuniger GmbH Schleuniger, Inc.

Raiffeisenstrasse 14 87 Colin Drive
42477 Radevormwald Manchester, NH 03103
Germany USA
P +49 (0)21 959 29-0 P +1 (603) 668 81 17
F +49 (0)21 959 29-105 F +1 (603) 668 81 19
[email protected] [email protected]
www.schleuniger.com www.schleuniger-na.com
Schleuniger AG Schleuniger Japan Co., Ltd.

Bierigutstrasse 9 4-5-8, Tokai, Ota-ku
3608 Thun Tokyo 143-0001
Switzerland Japan
P +41 (0)33 334 03 33 P +81 (0)3 57 55 80 41
F +41 (0)33 334 03 34 F +81 (0)3 57 55 80 45
www.schleuniger.com www.schleuniger.co.jp
Schleuniger AG Schleuniger Trading (Shanghai) Co., Ltd.

Business Unit Solutions 108, BH Center
Gewerbestrasse 14 7755 Zhongchun Rd
6314 Unteraegeri Shanghai, 201101
Switzerland China
P +41 (0)41 754 53 53 P +86 (21) 62 52 66 77
F +41 (0)41 754 53 50 F +86 (21) 62 40 86 55
www.schleuniger.ch www.schleuniger.cn
© 2015 Schleuniger | ID-0000000098-006-EN

Part #: 429 943
Order #:
2 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

Table of contents
TABLE OF CONTENTS
1 GENERAL 8
1.1 MANUFACTURERS ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 MANUFACTURING DATE / PRODUCT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.1 Contents of the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.2 Depository. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.3 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 GENERAL SYMBOLS AND LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.4.1 References and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 WARRANTY STATEMENTS AND POLICIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.8 COPYRIGHT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8.1 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.10 VALIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.11 MISUSE AND MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.12 ENVIRONMENTAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.13 SERVICE HOTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.14 UPDATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 SAFETY 15
2.1 WARNING NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.2 SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 SOURCES OF DANGER / RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 INTENDED USAGE OF PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 REASONABLY FORESEEABLE MISUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6.1 Danger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6.2 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7 SAFETY MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8 MODIFICATION AND RETROFITTING OF THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10 PERSONNEL QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.1 Personnel classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.10.2 Tasks / Authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.11 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.11.1 Eye protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Table of contents
2.11.2 Protective clothes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.11.3 Safety Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.11.4 Safety Gloves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.11.5 Snood-type cap or safety cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.12 SAFETY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 TRANSPORT / PACKAGING / STORAGE 28

3.1 SAFETY DIRECTIONS FOR THE TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1 Arbitrary transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.2 Improper transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 TRANSPORT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.3 UNPACKING / LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.4 LIFTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.1 The Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.2 Handling Packaging Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 INTERNAL TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.7 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4 PRODUCT SPECIFICATIONS 33
4.1 DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.3 PLANNING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.1 Installation Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.2 Electrical and Pneumatic Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.3 Position of the supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 MACHINE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 PRODUCT DESCRIPTION 39
5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2 CRIMPCENTER 36 S - CONFIGURATION POSSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.2.1 Assemblies of the Base Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.2 Processing Stations and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 PROCESSING CAPABILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.1 Available Processing Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.2 Available Quality Assurance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 CRIMPCENTER 36 S - POSSIBLE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4.1 Sample Configuration 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Table of contents
5.5 PROCESSING STATIONS AND OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.5.1 Overview of available Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.6 AVAILABLE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6.1 Depositing Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.7 SCOPE OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.7.1 Base Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.7.2 Required Basic Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.8 BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6 SAFETY ELEMENTS / DANGER AREAS 67

6.1 SAFETY COVER - PUSHBUTTON AND CONFIRM BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2 EMERGENCY STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.3 SAFETY COVER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.4 DANGER ZONES GENERALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.4.1 Danger Zones when Safety Cover is closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.4.2 Danger zones when Safety Cover is open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7 INSTALLATION / MOUNTING 76
7.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.2 POSITIONING / (DIS-) MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.2.1 Installing the Touch Screen.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.2.2 Removing the Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.3 ELECTRIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.3.1 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.4 PROCESSING STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8 COMMISSIONING 88
8.1 STARTING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2 MOUNTING THE TOOLINGSHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.3 ACTIVATE THE CRIMPCENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.4 OPEN THE SAFETY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.5 CONFIRM BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.6 ADJUST THE WORKING HEIGHT OF THE UNICRIMP 221/222 . . . . . . . . . . . . . . . . . . . . . . 96
8.7 MOUNT THE GUIDE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.8 INSERT WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.9 ADJUST THE CONTACT PRESSURE OF THE WIRE FEED . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.10 ADJUST THE CLAMPING FORCE OF THE GRIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9 SERVICING / MAINTENANCE 107

9.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.2 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2.1 General Safety Advice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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9.2.2 Personnel qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9.2.3 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.3 CUSTOMER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.1 Service Hotline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.2 Trouble Shooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.4 MAINTENANCE TABLE: BASE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.5 MAINTENANCE SHEET - CHECK SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.5.1 Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.5.2 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.5.3 Confirm Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.5.4 Safety Cover Pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.5.5 Safety Cover Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.5.6 Safety Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.5.7 Safety Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.5.8 Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.5.9 Pneumatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.5.10 Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.5.11 Power Sockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.6 MAINTENANCE SHEET - CHECK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
9.7 MAINTENANCE SHEET - SURFACE CLEANING AND PREVENTION . . . . . . . . . . . . . . . . . 139
9.7.1 Touch Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.7.2 PET - Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.7.3 Plastic / Rubber / Eladur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.7.4 Steel Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.7.5 Steel Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.7.6 Steel Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.7.7 Steel Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
9.7.8 Zinc Coated Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.7.9 Aluminum Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.7.10 Powdered / Painted Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
9.7.11 Tinning Station / Surrounding Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
9.8 MAINTENANCE SHEET - LUBRICATE GUIDE RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
9.9 MAINTENANCE SHEET - CLEANING THE CUTTER BLOCKS . . . . . . . . . . . . . . . . . . . . . . . .155
9.10 MAINTENANCE SHEET - EXCHANGING BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.11 MAINTENANCE SHEET - REFERENCE INITIAL POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.12 MAINTENANCE SHEET - REFERENCING CRIMPING STATION SIDE 1 . . . . . . . . . . . . . . . 180
9.13 MAINTENANCE SHEET - REFERENCING CRIMPING STATION SIDE 2 . . . . . . . . . . . . . . . 185
9.14 MAINTENANCE SHEET - EXCHANGE FEEDING BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.15 MAINTENANCE SHEET - DUMP CONDENSATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
9.16 MAINTENANCE SHEET - CLEAN FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.17 MAINTENANCE SHEET - FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
9.18 MAINTENANCE SHEET - CHECK CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

Table of contents
10 SPARE PARTS 200
11 DECOMMISSIONING / DISPOSAL 201

11.1 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
11.2 DISASSEMBLY / DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
12 OVERVIEW OF SYMBOLS 203
13 WIRING DIAGRAMS 210
INDEX 205

7 | 212
1. General
GENERAL
Thank you for your trust in the Schleuniger technique! You have acquired a high perform-
ance Schleuniger product, designed and manufactured in our factory to your needs. Read
through this manual with due care and attention. It contains important tips and safety
instructions, which allow precise and reliable wire/cable production.
1.1 MANUFACTURERS ADDRESS

Schleuniger GmbH Phone: +49 (0) 2195 929-0
Raiffeisenstrasse 14 Fax: +49 (0) 2195 929-105
42477 Radevormwald Email: [email protected]
Germany Web: www.schleuniger.com
1.2 MANUFACTURING DATE / PRODUCT TYPE

See “EC-Declaration of conformity“.
1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS

■ The Operating Manual is part of the product and contains all the relevant information
necessary to operate the product efficiently and safely as intended.
■ The mentioned safety notes and directions, as well as the valid local accident prevention
regulations and general safety regulations for the scope of application, must be com-
plied.
■ If the product changes hands, the Operating Manual must be supplied to the new own-
er.
■ Make sure to update any relevant safety changes and corrections to the Operating Man-
ual which are available.
Ask your local Schleuniger distributor.
1.3.1 Contents of the manual

General
Each person using the product must be properly trained and have red and understood the
Operating Manual. This is also imperative, even when the respective person has operated
such a product or similar previously and where they have been trained by the manufacturer.
The Operating Manual is:
■ In printed form the entire content of the folder according to the contents table.
■ In electronic form, this „Operating Manual“,
and the document „Parts List“
The Operating Manual is no longer valid, if any of its contents (except Quick Start Card,
where available) have been removed or on the data medium are not observed.
Construction
We are trying to make the operation of our products as easy as possible. To achieve this we
have developed a concept for the Operating Manual.
The Operating Manual consists of three parts:

1. General
Operating Manual - CrimpCenter

A detailed Operating Manual for the product with full explanation of all functions available
and the general maintenance. The Operating Manual is meant for the beginner as well as for
the experienced user (qualified personnel) as a learning- and reference guide.
See also chapter "2.10.1 Personnel classification (Page 23)".
Operating Manual - EASY User Software
A detailed Operating Manual for the operation of the user software CrimpCenter 36 S. The
Operating Manual is meant for the beginner as well as for the experienced user (qualified
personnel) as a learning- and reference guide.
Parts List
An overview on the components of the product. This part of the Operating Manual is inten-
ded mainly for the technical specialist.
1.3.2 Depository
The Operator's Handbook must be available to the operating personnel at all times. Keep
the Operator's Handbook in such a way that it will not become damaged, so that the con-
tents will remain clearly legible beyond the expected lifespan of the product.
1.3.3 Responsibilities
■ This Operator's Handbook must be kept near the product. It must be available to the
operating personnel at all time.
■ Always follow the instructions in this Operator's Handbook fully and without restraint.

9 | 212
1. General
1.4 GENERAL SYMBOLS AND LEGEND
1.4.1 References and Hints

The listed pictograms in the instructions have the following meaning:
Symbols
The symbols are placed in the marginal notes column and refer to the adjacent text. They
have the following meaning:
Symbol Meaning Description

Info Information which helps to operate the product efficiently and
error-free.
Overview Detailed description or introductional chapter.
Dispose-off Environmental contaminating substances to return to supplier.
1.4.2 Legend
In the text, mark-up is used in the following manner.
Mark-up Meaning Description

[SWITCH] Switch / button Commands and buttons on screen representa-
tions are in the text shown in squared brackets,
capital letters and orange colored.
„Configuration“ Screen title / menu Screen titles and menus are represented in the
text in "quotation marks".
Schleuniger Product names and Product- and company names are represented
company italic.
"1.4.2 Legend Cross referencing Cross referencing are represented in blue and
(Page 10)" italic.
1.▹ Activity direction Activity directions are a summary of activity
steps.
➥ Consequence of an Results or released actions in activity directions
activity direction are represented with a leading arrow.
The following abbreviations are used.
Abbreviation Meaning Description

Fig. Figure Figures are captioned as "Fig."
mm Millimeter All Measures in the manual are given in millime-
ters.

1. General
Abbreviation Meaning Description

CW Clockwise Direction of rotation for a component or an oper-
ating element viewed from rotation axis.
CCW Counter clockwise Direction of rotation for a component or an oper-
ating element viewed from rotation axis.
1.5 DECLARATION OF CONFORMITY

See document “EC-Declaration of conformity“.
1.6 LIMITATION OF LIABILITY

The content of these operating instructions was put together taking into consideration the
current standards and guidelines according to the state of the technology and our many
years of experience.
The manufacturer disclaims any liability for damages and accidents as a result of:
■ Disregard of the instructions.
■ Disregard of warning notices.
■ Use of the machine or processing stations not according to their intended use.
■ Use of parts not included in the approved product range.
■ Improper installation, initial operation, operation and/or maintenance.
■ Operation with safety equipment or protective covers not duly installed or not function-
ing well.
■ Failure to observe the operating instructions regarding transport, storage, installation,
initial operation, operation, maintenance and/or repair.
■ Supplement or modification of the machine or processing stations without written per-
mission of the Schleuniger GmbH.
■ Modification of the machine or adjoining assemblies or adjoining assemblies allowing
misuse.
■ Unauthorized structural alteration.
■ Inadequate control of parts which are subject to wear.
■ Improperly executed repairs.
1.7 WARRANTY STATEMENTS AND POLICIES

See Schleuniger document „General Conditions of Sale and Delivery”.

11 | 212
1. General
1.8 COPYRIGHT PROTECTION

Keep this Operating Manual confidential. It is intended for the exclusive use of persons oper-
ating the product. Without written permission of the manufacturer, this manual shall not be
made available to third parties.
The content of the Operating Manual in the form of text, illustrations, drawings, circuit dia-
grams or other presentations, is protected by copyright law of the manufacturer.
The same applies to copying, saving or distribution with electronic media.
1.8.1 Trademarks
Windows® (XP, Vista, 7 or CE) are registered trademarks of Microsoft Corporation in USA and
other countries.
All other brands or product names are trademarks or registered trademarks of their owners.
Registered trademarks are not specially marked in these instructions. However, this does not
mean that they can be used freely.

1. General
1.9 SPARE PARTS

Always order original spare parts from your local Schleuniger distributor.
CAUTION
Use of unverified spare parts!
■ Unverified or defective spare parts may lead to damage, malfunc-
tion or complete failure of the product.
■ Unverified or defective spare parts may impair the safety of the
operating personnel.
Exclusively use original Schleuniger spare parts only.
Any modifications in design or function of the spare parts, in terms of ongoing product
improvement, are subject to change without prior notification.
1.10 VALIDITY
This manual is valid for the following machine/s:
■ CrimpCenter 36 S Base machine (article number 422 029)
1.11 MISUSE AND MODIFICATIONS

Do not make any modifications to the machine or processing station and only utilize it for
the intended use.
See also chapter "2.4 Intended usage of product (Page 19)".
In particular please note:
■ Modifications lead to the loss of the guarantee by the manufacturer.
■ Modifications of adjacent components that enable misuse, also lead to the loss of guar-
antee.
■ Do not use any parts that are not included in the approved product range.
■ Do not use any accessories that do not correspond with the specified requirements.
■ Only use original spare parts.
■ If you want to change the basic operation of the machine or processing stations, contact
your authorized Schleuniger service partner.
1.12 ENVIRONMENTAL PROTECTION

Make sure that substances and materials are handled and disposed appropriately, in particu-
lar when working with lubricants and cleaning with solvents.

13 | 212
1. General
1.13 SERVICE HOTLINE

We suggest periodic maintenance by our service department.
Please contact your local sales and service partner.
For direct assistance from Schleuniger GmbH, Germany:
Service hotline Schleuniger GmbH, Germany Phone +49 (0) 2195 929 110
Email: [email protected]
1.14 UPDATING
Your safety is important to us. In order to remain up to date and receive information about
safety and security, please contact your local Schleuniger service partner.

2. Safety
SAFETY
2.1 WARNING NOTICES

The warning notices in the entire Operating Manual are marked with the following symbols.
They are headed by a safety alert symbol and the warning word which represents the
degree of endangerment.
To avoid any injuries or material damage it is essential that you read and fully understand
and follow these symbols.
DANGER
Warning notice „Danger”
This panel indicates a hazardous situation, which if not avoided, will
result in death or serious injury.
WARNING
Warning notice „Warning”
This panel indicates a hazardous situation, which if not avoided, could
result in death or serious injury.
CAUTION
Warning notice „Caution
This panel indicates a hazardous situation, which if not avoided, may
result in minor or moderate injury.
NOTICE
Warning notice „Property damage”
This panel indicates a hazardous situation, which if not avoided, can
result in damage to property.

15 | 212
2. Safety
2.2 SAFETY REGULATIONS

DANGER
Risk of injury
Check the safety devices of the machine yearly and
record the test.
Safety devices are:
■ all emergency stop switches
■ the safety cover with the safety switch(es)
■ the confirm buttons
■ The machine has been designed in accordance with the European Standard EN ISO
12100:2010 for persons above the age of 14 years. It is strictly forbidden to allow access
to the machine to persons younger than this age.
■ The product must only be operated when in good working order and condition. It must
be checked for intactness prior to the start of operation.
■ Never operate the product in an explosive or flammable environment.
■ Only operate the product in a dry, dust-free environment.
■ Never operate the machine without its safety cover.
■ Never work on the machine without wearing eye protection.
■ Only operate the product with connected earth conductor in the power cord.
■ Do not make any modifications to the machine and only utilize it for its intended pur-
pose according to section "2.4 Intended usage of product (Page 19)".
Other applications are only permitted with written approval of the manufacturer.
The manufacturer will accept no liability for damages resulting from disregard of this
regulation.
■ Never operate the machine without having red and understood all instructions first.
■ Train operators in their mother tongue.
If you would like to translate the operating instruction into another language, please
contact the manufacturer.
■ Repair work may only be carried out by authorized persons who have been specially
trained for this work.
■ Never switch on the machine during repair work.
■ Ensure that long hair is not worn loose, and do not wear loose clothing or ornaments
that could get caught in the moving parts of the machine.
■ Never deactivate or bypass the safety circuits, if the machine does not work correctly.
In this case switch off the machine and contact your Schleuniger service partner.
■ Processing stations must be tightly mounted on the support designated by Schleuniger
when starting production.
■ Take care that the work area is sufficiently illuminated.
■ Only use original Schleuniger equipment, especially interface connection cables (electro-
magnetic compatibility).
■ Compulsory operate the product connected to the Schleuniger emergency stop circuit, if
it is operated together with peripheral devices in a production line. Only then can a safe
interruption of the complete production line be guaranteed during an emergency.
■ Only use supplied lubricating grease according to the instructions given in this manual.
■ Any modification of the safety equipment is strictly forbidden.

2. Safety
Failure to do so may result in serious injury or death.

■ The CrimpCenter complies with the noise protection regulations.
In combination with other machines a permissible noise level can be reached. In this
case the operator has to place a mandatory-sign "Wear ear protection".
■ Through an increased noise level the communication of personnel can be more compli-
cated.
Through this hazards can occur.

17 | 212
2. Safety
2.3 SOURCES OF DANGER / RESIDUAL RISKS

With the use of technical products are dangers associated. Dangers that could not be elimi-
nated by design measures and also not by protection devices are residual risks. The safety
instructions in this instructions refer to the known residual risks. Should be shown additional
operational risks, the operator is obliged to inform Schleuniger immediately.
However, the following risks remain:
■ Danger due to catching body parts and clothing in the wire axis between peripheral
devices and the wire processing machine.
● Always close off these areas
■ Danger due to blocked wire/cable on the inlet. Tensile forces can move to overturn
machine, peripheral or bobbin and injure the operator personnel.
● Fixate machines and devices
● Ensure a continuing wire/cable supply
■ Danger of tripping, falling, slipping due to connection cables, wire residue and air hoses
lying around.
● Lay out connecting cables and hoses accordingly
● Collect wire residue
● Keep the area around free from non associated items.
■ Risk of tripping, falling and slipping on the ground.
● The floor must be technically proper and maintained.
■ Risk due to increased noise level while working in an environment with multiple
machines.
● Take up noise control measures!
■ Some wires/cables contain Talc. This contaminates the working environment during pro-
duction.
● Install the suction unit
● Wear a dust protecting mask
■ Crushing hazard in the area of the wire intake when engaging in the processing area of
the CrimpCenter.
● Only trained and qualified personnel is allowed to operate the machine
■ Danger of pulling in and/or catching of body parts and loose clothing in the area of the
wire feed and the wire intake in front of the wire processing machine.
● The operator has to ensure that the wires are led in a proper and safe way to the
machine
● The personnel has to wear tight-fitting clothes and close hair
● The area may only be entered by trained and qualified personnel
The operator has to instruct personnel relating to residual risks in periodic intervals.

2. Safety
2.4 INTENDED USAGE OF PRODUCT

WARNING
Caution, risk of injury, property damage!
Only use the product according to its intended use.
It is designed and manufactured exclusively for the following intended
application:
The CrimpCenter 36 S is an expandable fully automatic crimping
machine with up to six processing stations, depending on the configu-
ration.
According to the respective technical data, the CrimpCenter 36 S is suit-
able for the following purposes of the wire processing:
■ Cut to length
■ Stripping
■ Crimping (one or two sides)
■ Doubling crimp
■ Wire printing (Inkjet)
■ Coax cable processing
■ Good / bad part sorting
■ Wire stacking
■ Sealing
■ Twisting
■ Tinning
For further details see chapter "5.3 Processing Capabilities (Page 45)".
For better protection of the operator, the processing can be stopped at
any time.
The CrimpCenter 36 S is to be operated according to its intended use
and only with the processing stations and options as described in this
manual.
Schleuniger accepts no responsibilities for consequences resulting from
improper use. Any modification requires the written consent of the
Schleuniger GmbH.

19 | 212
2. Safety
2.5 REASONABLY FORESEEABLE MISUSE

■ The product must only be operated when in good working order and condition. It must
be checked for intactness prior to the start of operation.
■ Never operate the product in an explosive or flammable environment.
■ Only operate the product in a dry, dust-free environment.
■ Operate the product in an ambient temperature between 15-40°C.
■ To avoid any dangerous situations and for an optimal performance, it is not allowed to
make any modifications to, or retrofitting of the product, without explicit written permis-
sion of the manufacturer.
Thereof excluded are official options and accessories, provided for the product from the
Schleuniger GmbH.
The product CrimpCenter 36 S is not intended for the processing of materials with the follow-
ing characteristic:
■ Explosive
■ Flammable
■ Toxic

2. Safety
2.6 SAFETY SYMBOLS

In this manual, safety symbols are used which alert the user to potential hazards. They will
be described here in detail.
2.6.1 Danger
Symbol Description Description
Electric current There is danger of electric shock inside the machine.
Before opening the machine always switch off the main
switch and unplug the machine from the mains. Touching
electric components can cause serious injury or death to
the operating personnel.
2.6.2 Caution
Entanglement In case of carelessness there is a danger, that body parts
hazard or clothes can be pulled into the machine. Damages to
personnel or to property are possible.
Automatic start Machine can start automatically. The operator has to

ensure, that no other persons are in the area of the
machine.
Escaping pro- Wires can escape out of the machine on the wire exit area
cessed wire with high speed. Do not look into the wire ejection chan-
nel during the production! Escaping wires can injure eyes
and face.
Electric current There is a danger of electric shock by contact with parts

inside the machine and on the mains supply. Before open-
ing the machine always switch off the main switch and
unplug the machine from the mains. Touching electric
components can cause injury to the operating personnel.
Even if the machine is switched off the assemblies are
energized!
Material damage This sign indicates the possibility of serious damage.
Danger of crush- This sign warns you about the danger of crushing. You
ing may be injured if you do not observe this warning.

21 | 212
2. Safety

Risk of getting Motors and other electric components can get very hot
burned during operation.
There is a risk of getting burned!
The tinning station operates with hot tin.
Observe the safety advices in the operating manual of the
tinning station.
2.7 SAFETY MARKING

■ Safety markings affixed to the product, advert to possible danger situations and must be
strictly observed.
■ The safety markings must not be removed.
■ Damaged or illegible labels must be replaced immediately.
2.8 MODIFICATION AND RETROFITTING OF THE PRODUCT

To avoid any dangerous situations and for an optimal performance, it is not allowed to make
any modifications to, or retrofitting of the product, without explicit written permission of
the manufacturer.
Standard options and accessories supplied by Schleuniger are excluded.
2.9 RESPONSIBILITIES
The legal entity has to ensure, that every employee, working with the Schleuniger product
has received training in accordance with these operating manual (initial operation, opera-
tion, maintenance).
The training of the operating personnel has to include the following:
■ Purpose of the machine
See also section "2.4 Intended usage of product (Page 19)".
■ Danger areas
See also section "6 Safety elements / danger areas (Page 67)" .
■ Safety regulations
See also section "2.2 Safety Regulations (Page 16)" .
■ Ensure that personnel fulfills the required qualifications
See also section "2.10 Personnel qualification (Page 23)" .
■ General safety instructions and measures in case of emergency
■ Accident prevention regulations
■ Personal protective clothing
■ Operating the machine in accordance with these operating instructions

2. Safety
2.10 PERSONNEL QUALIFICATION

WARNING
Risk of injury if operated by unqualified personnel!
Improper handling of the machine may lead to serious injury to per-
sonnel and damage to the property.
The product is intended to be operated by personnel older than 14 years. It is strictly forbid-
den to grant access to younger persons.
For further information please contact the Schleuniger service.
2.10.1 Personnel classification

The following qualifications in these instructions are specified for the individual group of
persons.
Operating company
Creates operator´s instructions for the CrimpCenter.
■ Higher level juristic person

■ Authority to give directives
Qualification ■ Define competences
■ Accident prevention
■ First-aid measures
Schleuniger GmbH Specialist

Exclusively employees of the Schleuniger GmbH in Radevormwald.
Third Person
External persons attracted by Schleuniger
■ Partner
■ Personnel of the operating company
■ Service technician
■ Employees of Schleuniger
■ Mechanical and electrical training

■ Product-specific training
■ Application-specific training
■ Specialist in wire processing technique
Qualification
■ Has good command of English or German language
and the language of the operating personnel

23 | 212
2. Safety
Technical Specialists
■ Mechanical and electrical basic training
■ Know-how in wire processing techniques
Qualification
Electrically Qualified Person

■ Electrically training
■ Know-how in wire processing techniques
Qualification
Qualified Personnel
■ Technical skills
Qualification ■ Know-how in wire processing techniques
Operating personnel
Qualification ■ Accident prevention

2. Safety
2.10.2 Tasks / Authorities

The following tasks must only be executed by the specific groups of persons
Schleuniger GmbH qualified person

Electrically Qualified Person
Operating personnel
Operating company
Qualified Personnel
Technical specialist
Third Person
Task / authority
Train for the product ✓* ✓* ✓ ✓
Appoint personnel to the product ✓
Create operator´s instructions for the product ✓
Creates risk evaluations for the product ✓
Operate the product according to its intended ✓
use
Unpack the product ✓* ✓* ✓ ✓
Place the product ✓* ✓* ✓ ✓
Install the product ✓* ✓* ✓ ✓
Makes initial operation of the product ✓* ✓* ✓ ✓
Operates the product ✓ ✓ ✓ ✓ ✓ ✓
Setup the product ✓ ✓ ✓ ✓ ✓
Gives instructions for the product ✓ ✓ ✓ ✓
Maintains the product ✓* ✓* ✓ ✓
Cleans the product ✓ ✓ ✓ ✓ ✓ ✓
Repairs the product ✓* ✓* ✓ ✓*
Works on the pneumatic ✓* ✓* ✓ ✓
Works on the electric ✓* ✓* ✓ ✓
Modifies product ✓ ✓
Disassemble product ✓* ✓* ✓ ✓
Disposes the product properly ✓* ✓* ✓ ✓
*depends on the application specific training

25 | 212
2. Safety
2.11 PERSONAL PROTECTIVE EQUIPMENT

While working on the product, always wear protective equipment to minimize the risk of
injury.
■ Always wear protective equipment necessary for the work been carried out.
■ Observe the safety markings for the protective equipment in the working area.
2.11.1 Eye protection

To protect the eyes from small particles produced during wire/cable stripping and cutting.
2.11.2 Protective clothes

Wear tight-fitting clothes with low tensile strength and no protruding parts. Protects from
getting caught up in moving machine parts.
2.11.3 Safety Shoes

To protect from heavy, falling objects or reels.
2.11.4 Safety Gloves

Always wear cut resistant safety gloves when working close to the cutting unit, to protect
the hands and fingers against cuts.
Always wear heat resistant safety gloves when working close to hot surfaces or stations, to
protect the hands against burning.
2.11.5 Snood-type cap or safety cover

To protect long hair from getting caught up in moving machine parts.

2. Safety
2.12 SAFETY INSTALLATIONS

■ The built in safety devices on the machine (safety, protection, monitoring) must not be
removed, by-passed or modified.
■ The safety devices must be checked periodically.
■ Defective safety equipments must be fixed immediately before operation of the product
continues.
■ Never operate the machine/system without the safety cover.
■ Never operate the machine/system with the safety cover in open position.
■ The emergency stop buttons must always be accessible.
■ Do not remove any safety barriers.
■ Do not disconnect the emergency stop link between the machine and the peripheral
devices.

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3. Transport / packaging / storage
TRANSPORT / PACKAGING / STORAGE

During unpacking, transportation or storage of the product always observe the following
instructions. They contain important information to avoid injury to the operator and proper-
ty damage.
Take into consideration the weight of the machine during transportation, loading and posi-
tioning.
See also chapter "4.1 Dimensions and weight (Page 33)".
WARNING
Danger if operated by unqualified personnel!
The product must only be transported by accordingly trained person-
nel (Schleuniger personnel, qualified technical personnel on site).
WARNING
Risk of injury!
■ Falling objects may cause serious injuries!
Make sure that suitable load handling devices are available.
■ The maximum load of the load handling devices must not be
exceeded.
You will find the total weight of the machine on the rating plate
and in this manual.
See also chapter "4.1 Dimensions and weight (Page 33)".
WARNING
Risk of tilting!
The product is extremely top-heavy! It may tilt during transport and
cause serious danger.
■ Transport the CrimpCenter by means of a fork lift truck in horizon-
tal position.
Pay attention to the center of gravity of the machine!
■ While transporting the CrimpCenter with a fork lift truck secure it
with belts.
You will find on the CrimpCenter designated points to transport
the machine with a fork lift truck.
WARNING
Risk of accident!
■ Lift the CrimpCenter 36 S not too far above the ground.
■ Drive slowly and carefully.

3.1 SAFETY DIRECTIONS FOR THE TRANSPORT
3.1.1 Arbitrary transport

NOTICE
Damage due to arbitrary transportation!
Transportation by unqualified personnel may lead to extensive proper-
ty damage. Therefore:
■ Unloading and placing on site location must always be carried out
by qualified and trained personnel and under guidance of the man-
ufacturer.
■ Prevent any arbitrary transportation.
3.1.2 Improper transportation

NOTICE
Damage due to arbitrary transportation!
Transportation by unqualified personnel may lead to extensive proper-
ty damage. Therefore:
■ Handle with care and always observe the symbols and hints on the
packaging and the machine when unloading and placing on site
location.
■ Only use the intended transportation accessories.
3.2 TRANSPORT INSPECTION

Check the goods immediately after receiving for completeness and damages.
Proceed as follows, when there are visible transport damages:
■ Accept the delivery and note possible damages on the forwarding agent´s proof of deliv-
ery.
■ Determine extent of damage.
■ Immediately report damages on the machine.
NOTICE
Claim for damages!
Report any defect immediately after it was identified.

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3.3 UNPACKING / LOADING

NOTICE
Packaging notice!
If provided, observe the packaging notice on the machine.
■ Lift the machine carefully from the wooden pallet by the help of a mechanical appliance.
■ Remove all transport locks (cable ties, cords, foamed plastics) and check for free move-
ment of all accessible cylinders and drives.
(if available, observe packaging notes)
NOTICE
Remove the transport fixations!
■ Before initial operation of the machine, remove, if present, any
marked Transport fixations .
■ For later transportation store the transport fixations.
3.4 LIFTING POINTS
1 2
Lift the CrimpCenter 36 S only at the marked positions (1) and (2) with the hand lift truck or
with the fork lift.

1 2
Insert the fork lift teeth in the tilting protections (1) and (2).
3.5 PACKAGING
3.5.1 The Packaging

Store the packaging for later use on a weatherproof location.
3.5.2 Handling Packaging Material

The packaging consists of environment friendly materials such as wood, nails, cardboard,
paper and synthetics and can be recycled.
See chapter "11.2 Disassembly / Disposal (Page 202)".

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3.6 INTERNAL TRANSPORTATION

As applicable, transport the machine in the original packaging.
NOTICE
Position of center of gravity!
Danger through uneven weight balance.
■ During transportation, the machine can get out of balance or slip if
the position of center of gravity is not observed.
WARNING
Dislocation of packaging!
Danger from load dislocation.
■ During transportation in a craft, the product may slip off and cause
serious material damage.
■ Even the craft may start skidding, which could result in an accident
with incalculable consequences.
■ Always secure the product in the craft to prevent from slipping off.
Always reposition the machine with suitable utilities like a hand lift truck or a fork lift.
During transportation in a sloping terrain, the product must be secured properly so that it
cannot go away or slip uncontrolled.
3.7 STORAGE
Store the product under the following conditions:
■ Do not store outdoor.
■ Make sure that no condensation water accumulates on machine parts due to strong
thermal fluctuation. Do not remove wrapping and transportation locks, if any, until the
final place of installation is reached.
■ Protect the machine against tilting.
■ Slightly oil components of the product if it is stored a longer period of time.
■ If single component units of the machine are not installed immediately after delivery,
store them in a dry, protected and vibration-free place.
■ Make sure that the assemblies are not placed directly on the floor. Storage on planks is
recommended.

4. Product specifications
PRODUCT SPECIFICATIONS
This chapter among others gives an overview of the important technical specifications of
the product. Any modifications in design or function, in terms of ongoing product improve-
ment, are subject to change without prior notification.
4.1 DIMENSIONS AND WEIGHT
A C
Fig. 1: Layout machine
Description Value Unit

Weight CrimpCenter 36 S base machine 440 kg
CrimpCenter 36 S 750 kg
with 6 processing stations
Measures Width (A) 1573 mm
Depth (B) 1428 mm
Length of conveyor belt
depending on model (C)
Height with safety cover close 1885 mm
Height with safety cover open 2834 mm

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4.2 TECHNICAL SPECIFICATIONS

Description
Stations up to 6 processing stations (max. 3 crimping stations)
Min. wire length Standard 55 mm / 2.16" (crimp both sides)
Optional 35 mm / 1.38" (crimp both sides)
Wire cross section Standard 0.13* - 4 mm² (26* - 12 AWG)
* for cross sections smaller than 0.22 mm² (24 AWG) sampling
inspection is mandatory
Stripping length Side 1: 0.1 - 18 mm
Side 2: 0.1 - 18 mm
Wire feeding speed 1 - 8 m/s
Noise emission LpA=76+3db/A
Power source Electric - pneumatic
Power supply 3 / N / PE AC 400 / 230 V; 50 / 60 Hz.; 16 A
Air pressure 6 bar, not oiled, cleaned and filtered
Max. ambient tempera- 40° Celsius
ture
CE-compatibility The CrimpCenter 36 S complies with the CE and EMC equipment
guidelines (mechanical and electrical safety and electromagnetic
compatibility).
Notice The pictured machines can show variations which may not be the
actual contents of shipment. Variations in pictures, texts as well as
technical changes and errors excepted.
* Schleuniger recommends that wire samples be submitted in
cases where there is doubt as to the capabilities of particular
machines.

4.3 PLANNING DATA
4.3.1 Installation Location

DANGER
Danger of fire
There is a risk of fire caused by electric arc, electric shock and flying
sparks!
The operating company has to ensure that the machine is connected
according to the electrical connection data.
NOTICE
Danger of over heating!
Over heating may occur if the fan exhaust is blocked in any way.
Be careful, not to cover the aperture of the ventilators on the right and
left side.
■ The CrimpCenter 36 S is installed and operated as a stand-alone machine.
■ The maximum load of the ground must not be exceeded and it must be even.
■ Install the CrimpCenter 36 S in a horizontal and stress-free position using the installation
devices. Height from floor to the upper side of the aluminum base plate must be 31.6"
(790 mm). The height adjustable hinged feet must be secured by tightening the counter
nuts.
■ All power supply and control cables are to be properly installed and connected.
■ The operating company is responsible for the correct power supply. For a safe operation
the machine has to be connected according to the electrical connection data.
■ If there are additional applications installed on the machine, the documentation of the
specific manufacturer has to be considered.
■ Install and operate the CrimpCenter 36 S in a dry and dust-free room at an ambient tem-
perature between 15 - 40° C.
■ Prevent any reflections and glares on the touch-screen at the installation location.
■ In case of unfavorable conditions at the place of installation (for example extreme tem-
peratures, altitude, air humidity) the machine efficiency can be decreased. Try to
enhance the conditions, for example by using air conditioning.
■ If you have any technical questions, contact your local Schleuniger service partner for
more information.

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4.3.2 Electrical and Pneumatic Connections

Description Value Connection
Power supply
Power connection 210 - 500 VAC
Notice:
When the machine is equipped
with a transformer and is ship-
ped outside the European com-
munity there will be no CEE-
plug installed.
Line frequency 50 | 60 Hz
max. 6 Bar
Compressed air max. 0.6 MPA
Notice:
An air hose with an outer diam-
eter of 12 mm is installed on
the CrimpCenter
4.3.3 Position of the supply
Fig. 2: Position of the supply

4.4 MACHINE AREAS
B
A
Fig. 3: Machine Areas
Area Description
A Working area In this area the operator stays during production.
B Setup area In this area the operator / qualified personnel stays during setup.
C Maintenance In this area the trained service technician stays during mainte-
area nance.

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4.5 RATING PLATE

The rating plate is situated on the side of the machine and contains the following informa-
tion:
(the manufacturing date is included in the serial number)
1
2
3 10
4
5
6
7 11
8
9 12
13 13
13 13
Fig. 4: Rating plate
1 Manufacturer 2 Product
3 Machine type (model) 4 Serial # (contains manufacturing date)
5 Item number 6 Weight of the base machine
7 Required air pressure 8 Power frequency / Power input
9 Short circuit design 10 Date of checking according to DGUV -
V.3
(is marked)
11 CE-label 12 Barcode of the machine
13 Permissible mains voltage according to
order* (is marked)
*for further information please see chapter "4.3 Planning data (Page 35)".

5. Product description
PRODUCT DESCRIPTION
The CrimpCenter 36 S is a fully automatic crimping machine. It automatically produces one or
both side processed cables with high precision.
5.1 OVERVIEW
Depending on your machine configuration, a variety of processing stations can be integra-

ted. Typical processes include crimping, sealing, twisting and tinning of cable ends. The
machine is easily operated via touch screen. The CrimpCenter 36 S operating software EASY
features language-independent icons and unmatched user friendliness. With EASY you can
save and maintain your production parameters and retrieve all required data anytime you
produce an order anew.
Operating interface is designed ergonomically. In addition, an optional positioning help

(keypad) facilitates the setup of the swivel arms. Thanks to the positioning help it is no more
necessary running back to the touch screen during setup.
The CrimpCenter 36 S can be used as a stand-alone machine or fully integrated into a net-
work. Using international IT standard technology, integration is done quickly using your
existing infrastructure. The optional EASY ProductionServer (EASY PS) software allows you to
connect an unlimited number of CrimpCenter machines - whether they are located in the
same production hall or in different countries. Production orders can be managed centrally
and distributed to individual CrimpCenters. Whether you want to view real-time production
data or seek full integration with your production planning / ERP software: EASY Production-
Server is the right solution for you.

39 | 212
A variety of optional control and quality management tools are available for the CrimpCen-
ter series. Integrated check and control devices such as standard crimp force monitoring or
seal check ensure production on a consistently high technical level. EASY QualityCenter inte-
grates your quality and setup measurements into your CrimpCenter network.

5.2 CRIMPCENTER 36 S - CONFIGURATION POSSIBILITIES
5.2.1 Assemblies of the Base Machine
1 2 3 4 5 6
7 8 9 10 11 12
Fig. 5: Layout view
1 Pneumatic unit (beneath straighten- 2 Wire feed and swivel arm side 1
ing unit)
3 Cutting and stripping unit 4 Swivel arm side 2
5 Touch screen 6 Conveyor Belt
7 Cable barrel (optional) 8 Straightening unit
9 Sealing station (optional) 10 Safety cover
11 Crimping station (optional) 12 Operator

41 | 212
# Picture Description
1 Pneumatic unit (beneath straightening
unit)
■ Shut off valve
■ Main pressure regulator
■ Filter
■ Pressure regulator
Contact pressure for the wire feed
2 Wire feed and swivel arm side 1

■ Synchronous belt drive
(8 m/s)
3 Cutting and stripping unit

■ Quick change guides
■ Stripping blades side 1
(V-stripping blades)
■ Stripping blades side 2
(V-stripping blades)
■ Cutting blades
(top and bottom)
■ Rejected part cutting blades
(Rejected part cutting blade top and
bottom - bottom not visible)
4 Swivel arm side 2

5 Touch screen (with EASY software)
■ Illuminated push button On/Off
■ Confirm button
■ Button for safety cover
■ Emergency stop button
6 Conveyor Belt
7 Cable barrel (optional)
8 Straightening unit
(adjusting of wire / knot detection)
■ Perforated disc
■ Straightening roller
■ Quick change guides
9 Sealing station (optional)

10 Safety cover
11 Crimping station (optional)

12 Operator
5.2.2 Processing Stations and Options

The CrimpCenter 36 S fully automatic crimping machine has been configured with process-
ing stations and options according to your individual needs. Hence the scope of delivery is
according to your individual order. Attached to this manual or to the devices, you will find
their respective manuals.

43 | 212
We continuously expand the assortment of available stations and options. Because of the
modular design of the Schleuniger CrimpCenter 36 S it is often possible to change the config-
uration of your CrimpCenter 36 S later, to match your individual requirements. Ask your local
Schleuniger sale & service partner.

5.3 PROCESSING CAPABILITIES

The processing capabilities of your CrimpCenter 36 S depend on the model and your individ-
ual configuration (= installed processing stations and installed options).
Notice:
All information is subject to change without prior notice. Exceptions may depend on appli-
cation, wire and other variables. You might need additional devices or modifications of your
CrimpCenter 36 S to produce the displayed wires.
5.3.1 Available Processing Stations

The following table shows cable sections, which can be produced with your
CrimpCenter 36 S if the correct processing stations and options are installed.
The table below shows standard applications only. If you would like to perform other appli-
cations on your CrimpCenter 36 S, please do not hesitate to contact Schleuniger for a custom-
ized solution.
Picture Description
Measure and cut to length
Full strip both ends
Partial strip both ends
2-step strip both ends
Crimp to crimp
Crimp to crimp (closed barrel Additional software

terminals) required; centering unit
available
Crimp to seal 1 sealing station required
Seal to seal 2 sealing stations required
Twist, tin and crimp Twisting station and

tinning station required

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Picture Description
Horizontal and vertical dou- double gripper module
bling required
Doubling crimp double gripper module

(same terminals) required
Doubling crimp double gripper module

(different terminals) required
Doubling crimp with twisting, Tinning station, twisting sta-

tinning and crimp tion and double gripper
required
Doubling crimp with seal Double gripper module and
(same terminal and seal) sealing station required
Printing (Inkjet) Optional printer in the area

of the cutter head required
Hotstamp Hotstamp required
Wire list processing Requires optional software

(processing wires of different package enabling sequen-
lengths for minimizing waste) tial processing
Coax wire processing CoaxStrip 5400 required;
Crimping station required
for crimps
Twisting / tinning 2 twisting stations and
both sides 2 tinning stations
required
Twisting / tinning and seal Twisting station,
tinning station
and seal station
required

5.3.2 Available Quality Assurance

Quality assurance is an important factor in modern production facilities. The table below
lists both standard and optional quality assurance equipment. All options are available for
all CrimpCenter models.
Picture Description
Length encoder Standard
Good / bad sorting Standard
Horizontal and vertical wire Standard

straightener
Integrated Integrated in crimping sta-

Crimp force monitoring tions
Crimp height measuring Requires optional CHM

crimp height measuring
device
Electric crimp height adjust- Integrated in UniCrimp 222
ment
SealCheck Optional for sealing stations
Pullforce measurement Requires optional pullforce

measuring device
Terminal carrier strip cutter Optional for crimping sta-

tions
Splice detection Optional splice detection

(detects non-continuous wire / (SpliceCheck) required
missing insulation during wire
feeding)

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5.4 CRIMPCENTER 36 S - POSSIBLE CONFIGURATIONS

The following illustrations show different configuration possibilities of the CrimpCenter 36 S.
5.4.1 Sample Configuration 1

2 4
5 3
Fig. 6: Layout - Sample configuration 1

In this configurations the CrimpCenter 36 S is equipped with two crimping stations (4, 5).
No. Positioning Function Station

1 Base machine Wire feed
2 Base machine Swivel arm side 1
4 Side 1, station 1 Crimping station UniCrimp 221/222
Possible terminal feed

2 5 4
6 3

In this configuration the CrimpCenter 36 S is equipped with two crimping stations (5, 6) and
one sealing station (4).

4 Side 1, station 1 Sealing station SealLoad 3100

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2 5 4
6 7 3

In this configuration the CrimpCenter 36 S is equipped with two crimping stations (5, 7) and
two sealing stations (4, 6).


2 5 4
6 7 8 3

In this configuration the CrimpCenter 36 S is equipped with two crimping stations (5, 8),
two sealing stations (4, 7) and a double gripper module (6).

6 Side 2, station 1 Double gripper module SLD 4100

51 | 212
2 6 5 4
7 8 9 3

In this configuration the CrimpCenter 36 S is equipped with three crimping stations (5, 6, 9),
two sealing stations (4, 8) and a double gripper module (7).


2 5 4
6 7 8
8 3

In this configuration the CrimpCenter 36 S is equipped with three crimping stations (4, 5, 8),
one sealing station (7) and a double gripper module (6).


53 | 212
2 6 5 4
7 8 3

In this configuration the CrimpCenter 36 S is equipped with two coaxial stripping stations (4,
7),
a Crimping station with mounted twisting station (6) and
two tinning stations (5, 8).

4 Side 1, station 1 Coaxial stripping station CoaxStrip 5400
5 Side 1, station 2 Tinning station STS 1100

with twisting station with STW 1100
7 Side 2, station 1 Coaxial stripping station CoaxStrip 5400
8 Side 2, station 2 Tinning station STS 1100

5.5 PROCESSING STATIONS AND OPTIONS

The CrimpCenter 36 S can be fit to the individual requirements of your production. A number
of stations and options allow a wide range of applications.
5.5.1 Overview of available Stations

Station Picture Description
UniCrimp 221 Crimping station with integrated crimp
force monitoring and mechanical crimp
height adjustment.
SplitCycle function is optional available,
too.
UniCrimp 222 Crimping station with integrated crimp

force monitoring and electrical crimp
height adjustment.
SplitCycle function is optional available,
too.
SLU 3000 Sealing station for

loading seals on wires.
SealLoad 3100 Sealing station for

loading seals on wires.

55 | 212
Station Picture Description

SLD 4100 Double gripper module for processing
doubling crimps.
STW 1100 The twisting station twists stripped wire

ends.
STS 1100 The tinning station tins stripped wire

ends.
All information are subject to change without prior notice and are only an overview. You
might need additional devices mentioned in the remarks or modifications to your
CrimpCenter 36 S.

Crimping Station - UniCrimp 221

Crimping station with integrated crimp force monitoring CFM20.
UniCrimp 221
Crimping station with integrated crimp force monitoring CFM20
and adjustable support.
Crimp force Integrated / CFM20
monitoring
Crimp force 20 kN
Crimp height Manual adjustment
Stroke 40 or 30 mm
(can be changed mechanically)
Options ■ Applicator adapter, free from play
■ Carrier strip cutter and
collecting box
■ Guide plate
"Back Feed"
■ Accessory kit
for pneumatic applicators
■ Pneumatic wire centering device
for SplitCycle (closed barrel termi-
nals)
and software package
■ Several adapter kits
for customer specific applicators
e.g. JAM-applicator
All information is subject to change without prior notice. For
modifications and supplements please contact your local Schleu-
niger sales and service partner.

57 | 212
Crimping Station - UniCrimp 222

Crimping station with integrated crimp force monitoring CFM20.
UniCrimp 222
Crimping station with integrated crimp force monitoring CFM20,
electrical crimp height adjustment and adjustable support.
Crimp force Integrated / CFM20
monitoring
Crimp force 20 kN
Crimp height Electrical adjustment
Stroke 40 or 30 mm
(can be changed mechanically)
Options ■ Applicator adapter, free from play
■ Carrier strip cutter and
collecting box
■ Guide plate
"Back Feed"
■ Accessory kit
for pneumatic applicators
■ Pneumatic wire centering device
for SplitCycle (closed barrel termi-
nals)
and software package
■ Several adapter kits
for customer specific applicators
e.g. JAM-applicator

Sealing Station - SLU 3000

Sealing station for almost every type of seal including mini and hard-shell seals.
SLU 3000
Sealing station
Seal types Application sets
for more than 200 types of seals
Processing time approx. 200 ms
Options ■ Seal check
■ Remote control
for station adjustments (Pilot)
■ Seal expander
■ Tooling kits
■ Conversion kit
■ Cover sheets for sealing station
■ Various assembly tube inserts
■ Refilling of seals during production

59 | 212
Sealing Station - SealLoad 3100

Sealing station for almost every type of seal including mini and hard-shell seals.
SealLoad 3100
Sealing station
Seal types Application sets available for all types
of seals.
Processing time approx. 150 ms
Options ■ SealCheck
■ SealLevelMonitor with warning
light
■ Miniseal and hard-shell SealKits
■ Refilling seals during production
■ AdapterKit for the integration of
other seal kits
■ Spare parts kits
■ Setup gauge for AdapterKit
■ SealCleaner 20

Double Gripper Module - SLD 4100

Double gripper module for doubling crimp capability.
SLD 4100
Double gripper module
Wire diameter 1 - 4 mm
Doubling Horizontal and vertical (no mechanical
adjustment needed)
Options ■ Staged clamping jaws
(hold the wires tight and prevent
stripped wire ends from bending
apart)

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Twisting Station - STW 1100

Twisting station to twist stripped conductor end strands. Can be mounted in the frame of
the crimping station or separately.
STW 1100
Twisting station, can be mounted in the frame of the crimping
station or separately
Wire cross section up to 2.5 mm² / 14 AWG (depending on
wire up to 4 mm²)
Twisting length wire 4 - 18 mm
end 1
Twisting length wire 4 - 18 mm
end 2
Options ■ Separate support

Tinning Station - STS 1100

Tinning station for lead-free tin and integrated fluxing.
STS 1100
Tinning station
Tin Lead-free
Schleuniger recommends Cookson
Electronics SAC 305 lead-free tin with
3% silver, melting point 217° C, pro-
cessing temperature 295° C
Flux Integrated fluxing
Wire cross section Up to 2.5 mm² (14 AWG)
Operating temperature Max. 400° C
Options ■ Base frame, adjustable
■ Base frame, not adjustable
■ Drip protection for side 1
■ Drip protection for side 2
■ Various special nozzles depending
on required tin application

63 | 212
5.6 AVAILABLE OPTIONS

The following table lists all currently available options. Please check regularly with your
Schleuniger sales and service partner for new developments.
Options Description Requires

Crimping of closed barrel ter- Software package and
minals eventually centering unit
Long wires 2 or 4 meters conveyor

extension (more extensions
possible)
Crimp height measuring CHM
(crimp height measuring
device)
Electric crimp height adjust- Integrated in UniCrimp 222
ment
Seal check Optional for SealLoad 3100

and SLU 3000 sealing sta-
tion
Pullforce measurements PullTester
Wire printing Inkjet printer for high speed

printing
■ View production data EASY ProductionServer

online
■ Management of
production orders
■ Customized
ERP integration
Integration in existing net- EASY NetConverter
works using WPCS standard
Faster change-over of crimp- Quick-change unit

ing stations ToolingShuttle 30
(will be prepared outside of
the CrimpCenter)
Moving and store several Too- ShuttleRack for
lingShuttle 30 ToolingShuttle 30

Options Description Requires

Label printing Label printer
Entries Keyboard and mouse

with mouse and keyboard
Produce wires with different Wire list processing

lengths in one production
batch
Collect waste Waste container at the end
of the wire depositing tray
Reading barcodes (of wires, Barcode scanner

terminals, stations)
5.6.1 Depositing Table

# Representation Description
1 The depositing table is designated for
additional devices, like PullTester or
CHM.
Overloading may lead to permanent
damage of the depositing table.
The maximum load must not exceed
10 kg.

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5.7 SCOPE OF DELIVERY
5.7.1 Base Machine

The scope of delivery of the CrimpCenter 36 S base machine includes:
■ Standard transport belts for the feeding unit
■ Measuring wheel with encoder
■ Wire guides 1 - 5 mm
■ Standard clamping jaws
■ Slug container for rejected pieces
■ EASY software
■ Pivoting touch screen monitor
■ Standard PC with Windows ® operating system
■ Uninterruptable supply (UPS)
■ Operating manual
5.7.2 Required Basic Equipment

The following is not included in the base machine:
■ Wire straightener (horizontal and vertical)
■ Adjustable knot detection
■ Safety cover (CE-conform)
■ Cutter block top
■ Cutter block bottom
■ Cutting blades top
■ Cutting blades bottom
■ Reject contact blade top
■ Reject contact blade bottom
■ V-stripping blade 0.5 (set, 4 pieces)
5.8 BLADE
The V-blades are standard for the CrimpCenter.
Other blade variations are available, to improve the results depending on the application if
required.
We are pleased to support you with our experience.
Do not hesitate to contact the Schleuniger GmbH Service .

6. Safety elements / danger areas
SAFETY ELEMENTS / DANGER AREAS

DANGER
Observe the danger zones
You find an overview of the machine areas and the permitted person
groups in chapter "2.10.1 Personnel classification (Page 23)".
The complete area of the processing space underneath the safety cov-
er and in the area of the belt feed:
■ Danger from mechanical moving parts
■ Danger from electrical current
■ Danger from sharp-edged components
Outside the machine:
■ Danger from moving wires in the feeding area outside the machine
■ Risk of stumbling
The entire area of the machine and the base frame:
■ Danger from electrical current
■ Danger from sharp-edged components
The whole area of the conveyor belt:
■ Danger from moving parts
■ Danger from crushing at the pneumatic controlled tilting tray
Please observe the safety instructions of the processing stations
installed on your CrimpCenter!

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6.1 SAFETY COVER - PUSHBUTTON AND CONFIRM BUTTON

During production the area of the production space is protected by a safety cover. Opening
the safety cover is done with a pushbutton and is only necessary when rigging, setting up or
changing wires. It is not possible to produce while the safety cover is open. For setting up
the wire feed and the processing station it is necessary to press a confirm button simultane-
ously.
If the safety cover cannot close completely or gets blocked, the operator must open the
safety cover again and clear the blockage.
DANGER
Risk of injury
Prior to close the safety cover, the operator has to ensure, that no other
person is in the area of the machine.
WARNING
Risk of injury
Pressing the confirm button when the safety cover is open deactivates
some safety functions.
The person, which is actuating the confirm button, is responsible that
no other person is in the danger zones!
Only trained personnel are allowed to use the confirm button.
There are the following risks:
■ Crushing of fingers and hands by moving parts
■ Crushing of fingers and hands by the gripper
■ Pulling-in and catching of long open hair and / or loose clothing by
the feeding belts
■ Hitting of the upper extremities by moving parts
■ Shearing-off fingers by the cutting unit and the blades
■ Parts of the machine can move unexpected

Representation Description
Position of the pushbuttons
There is a pushbutton for the opening and
closing of the safety cover. They are on the
operator column.
■ Pushbutton for the
Opening of the safety cover (1)
Press the button shortly and release it to
open the safety cover half-way. Press it
two times and the safety cover opens
completely.
Closing of the safety cover (2)
Press and hold the button to close the
safety cover. As soon as you release the
button, the downward movement stops.
Press the button again and the down-
ward movement continues, until the cov-
1 er has reached its lowest position and
the cover is closed completely.
2
Position of the confirm buttons

It is not possible to produce, when the safety
cover is open. There are 3 confirm buttons to
allow some rigging and setting-up opera-
tions.
■ One confirm button is placed at the
pneumatic unit beneath the straighten-
ing unit

■ One button is placed on the operator
panel

69 | 212
■ One button is placed on the straighten-
ing unit
WARNING
Commissioning and setup work on the product must only be carried
out by specially trained personnel (Schleuniger Personnel, trained tech-
nical personnel on site).

6.2 EMERGENCY STOP SWITCH

The emergency stop button interrupts any power to the drives (axis) immediately. For this,
push the red button fully down until it snaps in. To disengage, turn it counterclockwise until
it snaps out.
All values entered while programming, are held in memory as the power to the software sys-
tem is not interrupted thereby.
Position of the emergency stop switches
■ Emergency stop switch (1)
■ Main circuit breaker (2)
1

1
NOTICE
Air pressure supply!
Activating the emergency stop switch does not interrupt the pressure
supply.
NOTICE
Misuse of the emergency switch!
Use the emergency stop button only in an emergency case. It should
not be used for the normal production stop.

71 | 212
6.3 SAFETY COVER SWITCH

Safety cover switch on the CrimpCenter
This safety switch (1) is coupled with the
safety cover (2) . It is not possible to produce,
when the safety cove is open.
Safety cover switch on the CrimpCenter
Safety cover switch complete

If the operator opens the safety cover during
2 production, a safe stop is initiated. The
machine stops the production immediately.
The motors are still in operational state how-
ever it is provided that the motors cannot
move.
NOTICE
Safety switch!
The safety switch ensures a safe and secure operation of the machine.

6.4 DANGER ZONES GENERALLY

The dangerous zones on the product are marked in the following figure. The operator must
also consult the chapter "2 Safety (Page 15)" to become familiar with the residual risks.
DANGER
Risk of injury / danger of life!
The product must only be operated by qualified operator personal.
There are danger zones where special caution is advised. Improper
handling can lead to injury or death.
DANGER
Risk of injury
Observe the use of the personal protective equipment.
Only trained personnel according to section „"2.10 Personnel qualifica-
tion (Page 23)" are allowed to stay close to the machine.

73 | 212
6.4.1 Danger Zones when Safety Cover is closed

Topview when safety cover is closed
1
2 3 4
Fig. 13: Topview - Safety cover closed
1 In the area of the wire feed

Danger of hand injury!
Danger of in-running nip!
Machine starts automatically!
2 Area in the machine base frame

The machine is equipped with a independent power supply.
Even if the machine is switched off the assemblies are energized!
Danger of electric shock!
3 In the area of the cable tray

There is a risk of crushing!
4 The area of the conveyor belt

Machine starts automatically!

4 The area of the conveyor belt

Danger due to escaping wires!
6.4.2 Danger zones when Safety Cover is open

Topview when safety cover is open
2 1
Fig. 14: Topview - Safety cover opened
1 In the area of the stations and the entire platform

Danger of hand injury!
2 Area in the machine base frame

The machine is equipped with a independent power supply.
Even if the machine is switched off the assemblies are energized!
Danger of electric shock!

75 | 212
7. Installation / Mounting
INSTALLATION / MOUNTING
7.1 SAFETY INSTRUCTIONS

The installation and commissioning instructions for the product have to be followed. The
following instructions must be followed step by step to avoid property damage on the prod-
uct and to reduce the risk of injury to the personnel to an absolute minimum.
WARNING
WARNING
Risk of injury!
The following instructions must be carried out in the listed sequence.
Improper handling may lead to injury.

WARNING
Activity advices!
The following security relevant points have to be specially observed:
■ Processing stations must be tightly mounted on the support desig-
nated by Schleuniger when starting production.
■ When handling inappropriate tools, you may suffer injuries. Always
use suitable tools.
■ Falling parts may cause injuries. Make sure that suitable load han-
dling devices are available. The maximum load of the load handling
devices must not be exceeded.
■ If the CrimpCenter 36 S is installed incorrectly, you may suffer inju-
ries.
■ The CrimpCenter 36 S is installed and operated as a stand-alone
machine.
■ The maximum load of the ground must not be exceeded and it
must be even.
■ Install and operate the CrimpCenter in a dry and dust-free room at
an ambient temperature between 15° - 40° C.
■ Make sure that no condensation water accumulates on the
machine parts due to strong thermal fluctuation.
■ Remove wrapping and transportation locks, if any, not before the
final place of installation is reached.
■ Install the CrimpCenter 36 S in a horizontal and stress-free position
using the installation devices. Height from floor to the upper side of
the aluminum base plate must be 31.6" (790 mm). The height
adjustable hinged feet must be secured by tightening the counter
nuts.
■ If there are additional applications installed on the machine, the
documentation of the specific manufacturer has to be considered.
■ The electric connection must be carried out by a technical specialist
and according to the local installation regulations.
NOTICE
Activity advices!
Please observe also the following points:
■ In case of unfavorable conditions at the installation location (for
example extreme temperatures, altitude, air humidity) the machine
efficiency can be decreased. Try to enhance the conditions, for
example by using air conditioning.
■ If you have any technical questions, contact your local Schleuniger
service partner for more information.

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7.2 POSITIONING / (DIS-) MOUNTING
7.2.1 Installing the Touch Screen.

For transport, the CrimpCenter 36 S touch screen is dismounted from the operator panel. It
will be shipped in the original packaging. The monitor is calibrated for each individual
CrimpCenter 36 S. The frame number of the CrimpCenter 36 S can be found on the packaging
of the monitor. For operating the CrimpCenter 36 S the touch screen must be installed at its
final position.
1. Locate the screws in a bag on the opera-
tor column of the CrimpCenter 36 S.
1.▹ Cut the cable ties and take out the
screws.
2.▹ Remove the monitor from the pack-
aging.
2. 1.▹ Mount the monitor holder with 3

screws on the operator column.
3. 1.▹ Connect the 3 connections (power

supply, USB-cable and sub-D moni-
tor cable) to the monitor.

4. 1.▹ Mount the cover sheet with
2 screws and countersink washers
on the front side.
5. 1.▹ Mount the cover sheet with

2 screws and countersink washers
on the back side.
7.2.2 Removing the Conveyor Belt

Prior to move the CrimpCenter 36 S to a new place, the conveyor belt as to be removed from
the base machine. Thereby observe the following points:
■ Never tear off cables and pneumatic hoses. Always disconnect the cables and tubes
appropriately.
■ Prior to release them, label the components and their position in relation to one another.
■ Label electric and pneumatic connections prior to disconnecting them

79 | 212
7.3 ELECTRIC INSTALLATION

DANGER
Risk of injury due to electric shock
Only technical specialists trained according "2.10 Personnel qualifica-
tion (Page 23)" to are allowed to install and connect the machine!
Training of staff shall be in compliance with government regulations.
■ Make sure to have equipotential bonding.
■ Use screened cables, data and control lines in environment
exposed to extreme electromagnetic radiation. Do not use cable
ducts.
■ When installing the machine, only use components which are in
compliance with the regulations on electromagnetic compatibility
according to the manufacturer.
■ Do not use any corroded connections. Clean them prior to connec-
tion or replace them.
■ The machine is equipped with a independent power supply. Even if
the machine is switched off electric components are energized.
DANGER
Risk of injury due to electric shock
Important when connecting the transformer:
■ Check the correct connection. Consult the wiring diagram.

7.3.1 Control cabinet

Open the control cabinet
1. The side panels of the control cabinet
consists of two parts (1, 2), which can be
removed.
Only the panels with the handles can
be removed!
Depending on the equipment of your
CrimpCenter 36 S some things need to be
prepared, before removing one or both
panels.
1 2
1.▹ Remove the ToolingShuttle 30 on
side 2.
If your CrimpCenter 36 S is equipped with
an electric paper winder, it should be
dismounted, in case it is placed in front
of the panel you want to remove.
The paper winder is fixed with 2 screws
on the underside of the platform.
1.▹ Remove the screws and take away
the paper winder.
2. The left side panel is mounted with 7
screws.
1.▹ Loosen the screws with a 4 mm Allen
wrench. Do not turn them out. They
only have to be loosened.
2.▹ After this the side panel can be
move to the left and removed to the
front.
Caution:
There is an earth equipment grounding
conductor connected to the side panel.
1.▹ Remove the connection before you
move the side panel away from the
CrimpCenter.
Make sure that you connect the cable
again, when mounting the side panel.
The assembly has to be done in reversed
order.

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3. ■ The right side panel is

mounted with 5 screws. Loosen the
screws with a 4 mm Allen wrench. Do
not turn them out. They only have to
be loosened.
■ After this the side panel can be move
to the left and removed to the front.
Attention:
There is an earth equipment grounding
conductor connected to the side panel.
Remove the connection before you
move the side panel away from the
CrimpCenter. Make sure that you con-
nect the cable again, when mounting
the side panel.
The assembly has to be done in reversed
order.

Transformator
1. ■ When the control cabinet is open,
you can locate the transformer in the
bottom right in the base frame.
■ The transformer is mounted in the
right area of the base frame behind
the right side panel. Only the right
panel has to be removed to connect
the machine to the power supply.
■ The connection must be accomplish-
ed according to the included wiring
diagram.
Attention:
Prior to initial operation it is absolutely
necessary to check the output voltage of
the transformer.
1.▹ Prior to initial operation it is abso-
lutely necessary to check the output
voltage of the transformer.

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Computer
1. For reasons of safety the computer of
you CrimpCenter has been removed
from the control cabinet and is packed
separately. The computer has to be
installed in the left side of the control
cabinet.
Only the left side panel has to be
removed to install the computer.
Through the hinged cover in the front
panel the computer and its ports can be
reached easily.
1.▹ To open the cover, remove the 2 cyl-
inder head screws and the cover can
be tilted to the front.
Attention:
Only trained personnel are allowed to
open the cover for service access.

Supplies
1. ■ The electric and pneumatic support
will be routed through the operator
column.

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7.4 PROCESSING STATIONS

The CrimpCenter will be shipped with the processing stations ordered.
Usually their position will not be changed.
The stations should only be mounted or dismounted by trained Schleuniger specialist.
Thereby observe the following points:
ATTENTION:
After changing the position of a station, check if the safety cover is still safe. The complete
area inside the safety cover has to be protected.
Therefore ask the Schleuniger GmbH service.
Picture Description
All stations are connected to the CrimpCen-
ter with power lines, control cables and
some with pneumatic hoses.
Prior to dismount the station, disconnect the
connections professional.
All stations are fixed with screws to the base

plate.
Before a station can be moved theses
screwed fastenings have to be loosened and
the screws have to be removed. The picture
beside shows the fastening screws of the
1 UniCrimp 221/222 support (two screws (1)
are not visible in the picture).
1
WARNING
Risk of tilting!
As soon as the screws are removed the station can tilt!

Picture Description
Processing stations can be very heavy.
Observe the weight specification on the rat-
ing plates of the stations.
Heavy stations, like the UniCrimp 221/222
are equipped with 2 lifting points.
The picture beside shows one of the lifting
points of a UniCrimp 221/222.
The other point is located on the other side
of the station.
■ Screw the 2 included M8 x 30 cylinder
head screws in these points and tighten
them (18 Nm +/- 1.5 Nm).
■ Lift the station exclusively at these points
with a load handling device by using
straps. The maximum load of the load
handling devices must not be exceeded.
Always observe the operating manuals of
the stations and the safety advices therein.

87 | 212
8. Commissioning
COMMISSIONING
Prior to initial operation the machine has to be in its final position. All transport locks must
be removed and all work steps in
chapter "7 Installation / Mounting (Page 76)" have to be executed.
WARNING
DANGER
Risk of injury
Prior to operating the following points have to be observed:
■ Make sure that all live components are covered appropriately.
■ When switching on the machine, all safety devices have to be
installed and functioning.
■ Make sure that no individuals are in the danger zones.
■ Observe the danger zones.
■ Make a visual inspection of all cables and pneumatic hoses. Defec-
tive cables and hoses are to be replaced by a specialist.
■ The stations of the CrimpCenter 36 S have their own operating man-
ual with safety advices, which have to be followed.
■ Processing stations must be tightly mounted on the support desig-
nated by Schleuniger when starting production.
■ Superiors must ensure that personnel have understood the opera-
tion and safety regulations.
DANGER
Risk of injury

8. Commissioning
8.1 STARTING CONDITIONS

The following conditions must be fulfilled to start the CrimpCenter 36 S machine.
■ The machine has to be properly mounted and connected to the power supply and the
pneumatic support.
■ Emergency stop switches not activated
■ Cables and hoses OK
■ Fuses OK
■ Power supply OK
■ Safety devices functioning
■ Pneumatic pressure OK
■ Main pneumatic valve open
■ Main circuit breaker (2)
1

1
Condition of the emergency stop switches

Emergency stop switch not activated

89 | 212
8. Commissioning
Condition of the emergency stop switches
Emergency stop switch activated
Overview pneumatic
Pneumatic unit
(beneath the straightening unit)
Symbols - overview
Shut off valve
Main pressure regulator
Water drain

8. Commissioning
Wire feed
Pneumatic - main valve

Pneumatic - main valve
in opened position
("Sup." = Supply)
Attention:
The moment the pneumatic valve is opened,
pneumatic controlled assemblies, for exam-
ple the gripper, can move automatically.
There is a risk of injury by crushing and by
automatic starting. Make certain, that no
persons are near the machine.

91 | 212
8. Commissioning
8.2 MOUNTING THE TOOLINGSHUTTLE

The ToolingShuttle combines the crimping applicator, the terminal reel and the paper spool
in a mobile quick changing unit for CrimpCenter fully automatic crimping machines. Instead
of changing the 3 elements separately, the preparation of a crimping station will be execu-
ted in one step. After changing the ToolingShuttle only the applicator has to be taken from
the ToolingShuttle and has to be fixed in the crimping station with the applicator clamp.
The ToolingShuttle is only used for crimping applicators with Side Feed.
ATTENTION:
Prior to start the machine make sure that all ToolingShuttles are mounted.
Even if the terminals are led from the back to the applicator (Back Feed) the ToolingShuttle
has to be mounted.
DANGER
Risk of injury
There is a risk of injury if there are no ToolingShuttles mounted.

8. Commissioning
8.3 ACTIVATE THE CRIMPCENTER

Main switch
■ Turn main switch ON.
Attention:
When you switch off the CrimpCenter with
the main switch or disconnect the machine
from the power supply, you have to wait at
least 5 minutes before restarting the
machine. This time the UPS (Uninterruptible
Power Supply) needs to shut down com-
pletely.
Starting Sequence
■ As soon as the CrimpCenter has been
switched on, the starting sequence
begins. The computer in the machine
base frame boots and the EASY user soft-
ware starts. You can log-in with your per-
sonal password when the log-in screen
appears.
■ Following the log-in you can setup and
configure according to your needs.
■ For further information about the oper-
ating with the EASY software please see
the EASY operating manual.

93 | 212
8. Commissioning
8.4 OPEN THE SAFETY COVER

Position of the pushbuttons
There is a pushbutton for the opening and
closing of the safety cover. They are on the
operator column.
Opening of the safety cover (1)
Press the button shortly and release it to
open the safety cover half-way. Press it
two times and the safety cover opens
completely.
Closing of the safety cover (2)
Press and hold the button to close the
safety cover. As soon as you release the
button, the downward movement stops.
Press the button again and the down-
ward movement continues, until the cov-
1 er has reached its lowest position and
the cover is closed completely.
2

8. Commissioning
8.5 CONFIRM BUTTONS

■ One confirm button is placed at the
pneumatic unit beneath the straighten-
ing unit

■ One button is placed on the operator
panel

■ One button is placed on the straighten-
ing unit

95 | 212
8. Commissioning
8.6 ADJUST THE WORKING HEIGHT OF THE UNICRIMP 221/222

■ The crimping stations UniCrimp 221 and
222 are adjusted to the lowest position
for transport.
■ Before initial operation of the CrimpCen-
1 ter, the crimping station has to be adjus-
ted to its working height.
■ Otherwise there will be a risk of collision
with the swivel arms.
Adjust the height with the ratchet ring
wrench (1).
■ There is a lever on the ratchet wrench.
■ With the lever in the left position (see
picture) using the wrench will move the
station down.
■ With the lever in the right position the
station will be moved up.

8. Commissioning
8.7 MOUNT THE GUIDE TUBES

1. 1.▹ Switch off the control voltage!
2. This is one of the guide tubes which will

1
be mounted in front of the wire feeding
belts.
Here you can see the diameter (1) of the
tube
Attention:
1.▹ Never operate the CrimpCenter
without the guide tubes. Otherwise
the feeding belts will be destroyed.
2.▹ The front and the back guide tube
should always have the same diame-
ter.
3.▹ The wire has to slide easily through
the guide tubes.
3. 1.▹ Put the guide tube fitting for your
wire diameter in front of the wire
feeding belts.

97 | 212
8. Commissioning
4. 1.▹ Press the guide tube down until it
snaps in.
5. This is one of the guide tubes which will

be mounted at the end of the swivel
arm..
Here you can see the diameter (1) of the
tube.
6. The picture shows the guide tube holder

in open position.
1.▹ The lever has to face towards the
cutting unit.
7. 1.▹ Put the guide tube onto the tube

holder.
The pin on the bottom will fit into the
boring of the holder.

8. Commissioning
8. The guide tube now lays on the holder.
It is not fixed yet.
9. 1.▹ Pull the lever towards the belts.

Now the guide tube is fixed.

99 | 212
8. Commissioning
8.8 INSERT WIRE

Double straightening unit
An optional double straightening unit is
available for the CrimpCenter 36 S.
■ This device allows the operator to pre-
pare the next wire during production.
■ Alternatively the double straightening
unit can be equipped with one straight-
ening device for the normal wire and one
for the thin wires.
1. 1.▹ Switch off the control voltage!
Straightening unit
2. Tension will be removed from the wire
and the wire will be checked for knots.

8. Commissioning
3. 1.▹ Turn the perforated disk to the
diameter you need.
2.▹ The wire should slide easily through
the disk.
4. 1.▹ Open the vertical straightening

device with the quick-lock.
1 2.▹ The position of the lower rail of roll-
ers (2) is pre-adjusted. With a slight
inclination the wire will be felted
stronger at first and then less and
less.
2
3.▹ If needed, the rail can be adjusted by
loosening the cylinder head screws
3 3
(3).
5. 1.▹ Open the horizontal straightening

6. The wire will be guided through the

ceramic bushing.

101 | 212
8. Commissioning
7. 1.▹ Insert the wire and check that it has
enough play in the ceramic bushing
and the perforated disk.
8. 1.▹ Lead the wire through the vertical

straightening device.
9. 1.▹ Close the vertical straightening

The wire must be slightly deformed by
the rollers (see picture).
1.▹ If necessary correct the distance of
the rollers with the fine adjustment.
10. 1.▹ Lead the wire through the horizontal

straightening device and do the
same as before.

8. Commissioning
11. 1.▹ Open the wire feeding belts of the
swivel arm.
Therefore use the trigger switch.
12. The first part of the wire should be as

straight as possible and there must not
be any curves.
If necessary straighten the wire manual-
ly.
1.▹ Lead the wire through the first wire
guide.
13. 1.▹ Insert the wire guide with the wire in

front of the feeding belts.
14. 1.▹ Press the guide tube down until it

snaps in.

103 | 212
8. Commissioning
15. 1.▹ Push the wire up to
approx. 10 - 15 mm between the
belts.
2.▹ Please observe that the wire is
straight and that it lays in the middle
of the belts.
16. 1.▹ Close the feeding belts.

Therefore use the trigger switch.
17. 1.▹ Press the confirm button and the

feeding button simultaneously.
The CrimpCenter will take in the wire.
18. 1.▹ Hold down both buttons until the

wire comes out of the front of the
guide tube.

8. Commissioning
8.9 ADJUST THE CONTACT PRESSURE OF THE WIRE FEED

1. The force of the contact pressure from
the wire feed will be adjusted by a pres-
sure regulator beneath the straightening
unit.
The pressure has been adjusted by
Schleuniger at the final check.
Due to the special construction of the
swivel strip arm, it is usually not necessa-
ry to adjust the pressure for different
cross sections.
The default setting is 5 bars.

105 | 212
8. Commissioning
8.10 ADJUST THE CLAMPING FORCE OF THE GRIPPER

1. On the back of the column of
swivel arm side 2 is the pressure regula-
tor for the gripper side 2.
1.▹ Adjust the pressure so that on one
hand there are no marks of the grip-
per on the wire, and on the other
hand the gripper will hold the wire
during the stripping process without
slipping through.
The upper pressure regulator is only
available when a double gripper is instal-
led.
If there is a double gripper installed and
activated in the EASY software, only the
upper pressure regulator sets the pres-
sure of the gripper side 2.
When the double gripper is not activa-
ted the upper pressure regulator is with-
out function.

9. Servicing / Maintenance
SERVICING / MAINTENANCE
9.1 INTRODUCTION
All exchangeable mechanical elements of the CrimpCenter 36 S are fixed by means of screws
and bolts. The positions for the fixation of the spare parts are thus defined.
If you replace components such as buttons, sensors or limit switches, they must be fixed in a
way to allow required function.
Check the replaced parts for functioning prior to restarting the CrimpCenter 36 S machine!
The "Maintenance table: Base machine", includes the following:
■ Maintenance of component units
■ Activities
■ Material needed
■ Reference to further information
■ Maintenance interval
The maintenance sheets (base machine) comprise information on how to perform mainte-
nance and repair. Keep the CrimpCenter 36 S in an operational and safe condition when exe-
cuting these activities.
Observe the safety instructions given in the maintenance sheets. The maintenance sheets
appear in the same order as listed in the maintenance table.
For maintenance of the processing stations and optional accessories see the documentation
of the manufacturer and observe the safety instructions as described by the manufacturer.
We suggest a periodic maintenance by our service department.

107 | 212
9.2 SAFETY INSTRUCTIONS
9.2.1 General Safety Advice

DANGER
Danger because of insufficient safety!
Observe the following points prior to and during maintenance work.
Disregard may lead to serious injury or death:
■ Switch off the CrimpCenter!
■ Set the main switch in position "0 OFF", and lock it in this position.
■ Attach a sign to the main machine indicating the following:
"Do not switch on the machine".
Take appropriate measures to ensure, that no other person can
restart the machine.
■ Observe the advices in the chapter "Safety".
■ After finishing maintenance and repair work restore the safe opera-
tion status.
Reinstall all safety devices.
The safe operation of the CrimpCenter is thereby ensured.
■ Monitor the CrimpCenter when activating it after maintenance and
repair.
In case of malfunction, immediately switch off the CrimpCenter
machine with the emergency stop.
■ Use suitable tools only!
Only proper functioning tools are to be used for maintenance and
repair.
When improper, unsuitable or damaged tools are used, you may
suffer serious injuries or damage to the machine.
■ Always follow the maintenance and safety instructions of the man-
ufacturer´s documentation when doing maintenance or repair
work on processing stations or options.
WARNING
Risk of injury
There are the following risks:
■ Crushing of fingers and hands by moving parts
■ Crushing of fingers and hands by the gripper
■ Pulling-in and catching of long open hair and / or loose clothing by
the feeding belts
■ Hitting of the upper extremities by moving parts
■ Shearing-off fingers by the cutting unit and the blades
■ Parts of the machine can move unexpected

DANGER
Risk of injury
If the safety cover is open there are the following risks:
■ Risk of burns to fingers and/or hands by activities, e.g. on motors,
after they have been in operation for a longer time.
Observe the warning signs!
Wear protective equipment!
■ Risk of burns to fingers and/or hands when a tinning station is
installed.
Observe the warning signs!
■ Risk of shearing of fingers and/or hands by the closing of the cutter
blocks
9.2.2 Personnel qualification

WARNING
Maintenance and repair work shall only be executed by qualified and
trained staff.
See also chapter "2.10 Personnel qualification (Page 23)"
This ensures that the CrimpCenter 36 S is repaired properly.
Duly executed repairs ensure that the original safety standard is
restored.
9.2.3 Personal protective equipment

See chapter "2.11 Personal protective equipment (Page 26)".

109 | 212
9.3 CUSTOMER SERVICE
9.3.1 Service Hotline

In the case of technical problems with the machine, we recommend our customers to con-
tact the local Schleuniger distributor first, see „http://www.schleuniger.com“.
9.3.2 Trouble Shooting Procedure

If problems occur, which cannot be solved by the help of this manual, the Schleuniger dis-
tributor or the technical staff of Schleuniger is ready to assist you.
In such situations it is essential to provide a precise description of the matter:
■ Exact type of machine
■ Serial number of the machine
■ Software version (incl. language packages, PLC-versions, Workflow versions)
■ Exact description of error
(Error no. shown on the screen, if available)
■ Under what circumstances has the error shown up
■ What peripheral devices where connected to the machine when the error occurred
■ Wire type to be produced at the time the error occurred

9.4 MAINTENANCE TABLE: BASE MACHINE

Maintenance work must be accomplished according to the instructions and the time inter-
vals listed. Generally proceed according to the following chart:
The duration and the interval of the maintenance of the maintenance sheets "9.5.1 Check the
main switch (Page 115)" up to "9.5.11 Power Sockets (Page 136)" are summarized in the main-
tenance sheet"9.5 Maintenance Sheet - Check Safety Devices (Page 114)".
The duration and the interval of the maintenance of the maintenance sheets "9.7.1 Cleaning
the touch screen (Page 141)" up to "9.7.11 Tinning Station / Surrounding Parts (Page 152)" are
summarized in the maintenance sheet"9.7 Entire machine (Page 139)".
Maintenance task Page Duration Interval Personnel qualification

Check all safety devices (114) approx. 30 Yearly "2.10 Personnel qualification
min. (Page 23)"
Check the main switch (115) - - "2.10 Personnel qualification
(Page 23)"
Check all emergency stop (117) - - "2.10 Personnel qualification
buttons (Page 23)"
Check all confirm buttons (120) - - "2.10 Personnel qualification
(Page 23)"
Test the pneumatic valves (122) - - "2.10 Personnel qualification
of the safety cover. (Page 23)"
Checking of the safety cov- (124) - - "2.10 Personnel qualification
er safety switch (Page 23)"
Check the closing force of (126) - - "2.10 Personnel qualification
the safety cover (Page 23)"
Check the closing of the (128) - - "2.10 Personnel qualification
safety cover (Page 23)"
Check the standstill moni- (129) - - "2.10 Personnel qualification
toring (Page 23)"
Check the shut-off valve (133) - - "2.10 Personnel qualification
(Page 23)"
Check conveyor belt (134) - - "2.10 Personnel qualification
(Page 23)"
Check the power sockets (136) - - "2.10 Personnel qualification
(Page 23)"
Checking complete (138) approx. 20 Yearly "2.10 Personnel qualification
machine min. (Page 23)"
Entire machine (139) approx. 30 Weekly "2.10 Personnel qualification
min. (Page 23)"
Cleaning the touch screen (141) - - "2.10 Personnel qualification
(Page 23)"
Cleaning PET-surfaces (142) - - "2.10 Personnel qualification
(Page 23)"

111 | 212

Cleaning plastic, rubber (143) - - "2.10 Personnel qualification
and Eladur (Page 23)"
Cleaning steel surfaces - (144) - - "2.10 Personnel qualification
stainless steel (V2A) (Page 23)"
crude steel (not gliding) (Page 23)"
crude steel (guide rails) (Page 23)"
nitrified steel (Page 23)"
Cleaning zinc coated surfa- (149) - - "2.10 Personnel qualification
ces (Page 23)"
Cleaning aluminum surfa- (150) - - "2.10 Personnel qualification
ces (Page 23)"
Cleaning / repairing of (151) - - "2.10 Personnel qualification
powdered / painted surfa- (Page 23)"
ces
Cleaning tinning station (152) - Daily prior "2.10 Personnel qualification
and surrounding sheets to start (Page 23)"
and parts with work
Lubricate the guide rails (153) approx. 5 Yearly "2.10 Personnel qualification
min. (Page 23)"
Cleaning cutter blocks and (155) approx. 10 Weekly "2.10 Personnel qualification
surrounding parts min. (Page 23)"
Blade change (157) approx. 20 Individual "2.10 Personnel qualification
min. (Page 23)"
Reference initial position - (160) approx. 20 Individual "2.10 Personnel qualification
Swivel arm side 1 and 2 min. (Page 23)"
Referencing initial position (180) approx. 15 Individual "2.10 Personnel qualification
- Swivel arm side 1 and min. (Page 23)"
crimping station
Referencing initial position (185) approx. 15 Individual "2.10 Personnel qualification
- Swivel arm side 2 and min. (Page 23)"
crimping station
Exchange feeding belts (190) approx. 30 Individual "2.10 Personnel qualification
and check belt tension. min. (Page 23)"
Dump condensate (193) approx 1 Monthly "2.10 Personnel qualification
min. (Page 23)"
Clean filter (194) approx. 5 Yearly "2.10 Personnel qualification
min. (Page 23)"
Check and exchange filter (196) approx. 10 Weekly "2.10 Personnel qualification
elements min. (Page 23)"


Check conveyor belt (199) approx. 5 Weekly "2.10 Personnel qualification
min. (Page 23)"

113 | 212
9.5 MAINTENANCE SHEET - CHECK SAFETY DEVICES
Check all safety devices
Task Check safety devices and report

Unit Entire machine
Duration approx. 30 min.
Interval Yearly
Personnel qualification "2.10 Personnel qualification (Page 23)"
Protective equipment "2.11 Personal protective equipment (Page 26)"
Parts ■ See below
The operating company has to make sure that the safety devices are checked yearly accord-
ing to the following instruction.
The checks must be recorded.
It is recommend taking the checks into the operator instruction.
If one of the tests is negative, stop the machine! Immediately contact the Schleuniger
service.
WARNING
Qualified personnel
The test and report may only be executed by technical specialists.

9.5.1 Main switch
Check the main switch
Task Check the main switch off the CrimpCenter.

Unit Entire machine
Duration -
Interval -
Parts ■ No material required
service.
WARNING
Qualified personnel

115 | 212
Task
1. The main switch must not have any
mechanical damages and has to be
properly seated.
1.▹ Switch off the CrimpCenter with the
main switch.
Wait approximately 5 minutes until the
uninterruptable power supply has shut
down.
The touch screen is off.
Pictures may differ from your product.

2. All illuminated pushbuttons on the oper-
ator column are off.

9.5.2 Emergency Stop Switch
Check all emergency stop buttons
Task Check the emergency stop buttons for function and damages.
Unit Entire machine - safety cover, UniCrimp 221/222, paper winder
Duration -
Interval -
service.
WARNING
Qualified personnel
The emergency stop button interrupts the power supply of the motors and switches them
powerless.
To do so the button has to be pressed down until it snaps in.
To disengage the button it has to be turned counterclockwise.
Task
There are 2 emergency stop buttons on
the machine.
See chapter "6.2 Emergency Stop Switch
(Page 71)".
They must not have any mechanical
damages and have to be properly seat-
ed.

117 | 212
Task
1. EASY software
Switch on the CrimpCenter if necessary.
1.▹ Bring the CrimpCenter with the
highlighted button in the EASY soft-
ware in its initial position.
Because the safety cover is open,
one of the confirm buttons has to be
pressed.
2. 1.▹ Press one of the emergency buttons.
3. Check the functionality of all emergency

stop buttons as follows:
1.▹ Move the safety cover into top posi-
tion.

4. 1.▹ Try to close the safety cover.
When the emergency stop button works
correct, this is not possible.
5. All motors are powerless and can be
moved easily.
Pictures may differ from your product. 1.▹ Check the swivel arms and, if exist-
ing, the pull-off units.
6. The conveyor belt does not rotate.
7. The slide of the UniCrimp 221/222 can-
not be moved with the buttons for man-
ual operation.

Task
8. 1.▹ Press the deflection plate of the Too-
lingShuttle towards the applicator.
The motor of the paper winder must
not rotate.
(Picture: CrimpCenter 36 S)
9. The emergency button is locked.
The left picture shows the button in
unlocked position.
The right picture shows the button in
locked position.
10. 1.▹ Release the emergency stop button.
The machine must not start auto-
matically.
11. 1.▹ Repeat the test with all emergency
stop buttons.

119 | 212
9.5.3 Confirm Buttons
Check all confirm buttons
Task Check the confirm buttons for mechanical, proper seat and func-
tion.
Unit Entire machine - Confirm buttons
Duration -
Interval -
service.
WARNING
Qualified personnel
Task
There are 3 confirm button on the
machine.
See chapter "6.1 Safety Cover - Pushbut-
ton and Confirm Button (Page 68)".
They must not have any mechanical
damages and have to be properly seat-
ed.
1. EASY software
Switch on the CrimpCenter if necessary.
1.▹ Go to the Sample menu and open
the safety cover.
All 3 confirm buttons have to light up
constantly.
In the EASY software the button for the
initial position is grayed.

Task
2. 1.▹ Test one confirm button by pushing
and holding it.
2.▹ Do not execute any other actions.
This status will be displayed in the EASY
software by a graphic.
3. After approximately 5 seconds the but-

ton starts to flash.
The graphic in EASY changes.
4. After flashing a few seconds the button

goes out and is without function.
1.▹ Test each confirm button.

121 | 212
9.5.4 Safety Cover Pushbutton
Test the pneumatic valves of the safety cover.
Task Check the pneumatic valves of the safety cover.

Unit Entire machine - Safety cover, operating column. pneumatic unit
Duration -
Interval -
service.
WARNING
Qualified personnel
There is a button for opening and a button for closing the safety cover.
Both buttons must not have any mechanical damages and has to be properly seated.
Some settings for the safety cover can be defined in the EASY module "Safety cover". The
following instructions refer to the factory default settings.
Task
1.▹ Press the pushbutton once for open-
ing the safety cover.
The safety cover opens halfway.

1.▹ Switch on the control voltage.
2.▹ Close the safety cover.

Task
1.▹ Press the pushbutton for opening
the safety cover twice.
The safety cover opens halfway.

1. Execute the following inspection
1.▹ Open the safety cover completely.
2. 1.▹ Close the main valve.
(Direction of rotation: counterclock-
wise)
3. 1.▹ Switch on the control voltage.
4. 1.▹ Press the pushbutton to close the
safety cover.
The cover must not move downwards.

123 | 212
9.5.5 Safety Cover Switch
Checking of the safety cover safety switch
Task Check the safety cover safety switch.

Unit Entire machine - Safety cover, operating column. pneumatic unit
Duration -
Interval -
service.
WARNING
Qualified personnel
The safety cover safety switch monitors if the safety cover is open or close.
Task
Safety cover
The catch is mounted on the safety cov-
er, the switch on the base machine.
The left picture shows the catch and the
right picture shows the switch as an
example on the CrimpCenter 36 S.
Each, the catch and the switch, must not
have any mechanical damages and have
to be properly seated.

Task
When the safety cover is closed the
catch has to snap into the switch.
The catch or its fixing screws must not
rest on the switch.
The picture shows that there is space
between the catch and the switch.
EASY software
When the safety cover is open the
machine works only in manual opera-
tion. This means that e.g. in the "Sample"
menu the confirm button has to be
pushed to execute actions with the
machine.
1. Execute the following test:

2. 1.▹ Start production
3. 1.▹ Lift the safety cover during produc-
tion with two persons carefully and
simultaneously up.
After approx. 2 cm lifting:
4. 1.▹ An EASY error message has to
appear and the machine stops.
5. 1.▹ Close the safety cover.
After the safety cover has closed com-
pletely the machine must not start auto-
matically.

125 | 212
9.5.6 Safety Cover
Check the closing force of the safety cover
Task Check the closing force of the safety cover.

Unit Safety cover
Duration -
Interval -
Parts ■ Spring balance (measuring range 150N +- 50N)
service.
WARNING
Qualified personnel

Task
1. 1.▹ Hang up a spring balance on the
safety cover.
On a CrimpCenter 36 S use the bottom
corner of the safety cover (between the
angled edges).
2. 1.▹ Close the safety cover.
2.▹ When the safety cover has moved
down half the way, hold fast the
upper end of the spring balance.
It must not move downwards or
upwards.
Pictures may differ from your product. 1.▹ Now read the measured value on
the spring balance.
For 6 - 7 seconds the value must be
150 N.
In this case the closing force is correct.

127 | 212
9.5.7 Safety Cover
Check the closing of the safety cover
Task Check the safety when the safety cover closes.

Unit Safety cover
Duration -
Interval -
If one of the tests is negative, immediately contact the Schleuniger service.
WARNING
Qualified personnel
Task
1. 1.▹ Open the safety cover.

2. 1.▹ Place a helper on each side of the
safety cover
3.▹ When the safety has moved down
approximately half way, both helper
stop simultaneously the safety cov-
er.
After approx. 7 seconds the safety cover
should open automatically.

9.5.8 Motors
Check the standstill monitoring
Task Check the standstill monitoring of the motors.

Unit Entire machine - motors, swivel arms, control cabinet
Duration -
Interval -
service.
WARNING
Qualified personnel
The standstill monitoring ensures that the servo motors of the CrimpCenter will be switched
powerless, when one of the axes has left its position without movement command.
Task
1. EASY software
1.▹ Open the menu "Sample" or "Pro-
duction"
2. Operating unit
1.▹ Open the safety cover.

129 | 212
Task
3. EASY software
1.▹ Bring the machine into initial posi-
tion.
To do so one of the confirm buttons
has to be pressed.
4. 1.▹ After the machine has stopped the
movement release the confirm but-
ton.
5. Swivel arm side 2

1.▹ Carefully try to move the swivel arm
side 2.
A resistance must be noticeable.
6. 1.▹ Afterwards move the swivel arm
with force out of the current posi-
tion.
7. EASY software
As soon as the resistance ha been over-
powered an error message in the EASY
software appears.
"SPS51001021 Motor lost position when
cover open"
1.▹ Now the swivel arm can be moved
easily.

Task
8. 1.▹ Confirm the error message.
2.▹ Go to menu "Sample" or "Produc-
tion".
9. 1.▹ Bring the machine with the highligh-
ted button back in initial position.
10. Control cabinet

1.▹ Open the control cabinet.
11. The modules of the standstill monitoring
are in the control cabinet.
12. 1.▹ Check the highlighted LEDs "Speed
1" on the modules K17, K18 and K19
(see next picture).
The labeling is beneath the LED´s.

131 | 212
Task
13. The picture shows the 3 highlighted
LEDs "Speed 1" of the modules K17,K18
and K19.
All 3 LEDs glow.
14. EASY software

1.▹ Move one of the swivel arms until
the error message "SPS51001021
Motor lost position when cover
open" appears.
15. Control cabinet

Now one of the LEDs has to be off.
16. Furthermore the lamps on the top left

corners of the Acopos controllers are
blinking.

9.5.9 Pneumatic
Check the shut-off valve
Task Check the shut-off valve of the pneumatic unit.

Unit Pneumatic unit
Duration -
Interval -
service.
WARNING
Qualified personnel
Task
1. 1.▹ Close the main valve.
(Direction of rotation: counterclock-
wise)
The pressure gauge must not show any
pressure.

133 | 212
9.5.10 Conveyor Belt
Check conveyor belt
Task Check the deflector plate of the conveyor belt.

Unit Conveyor Belt
Duration -
Interval -
service.
WARNING
Qualified personnel
The deflector prevents cable waste from getting thrown out of the conveyor belt in a
straight line and deflects it downwards.
The optional waste container securely collects the leavings.

Task
There has to be a deflector or a waste
container at the end of the conveyor
belt.
This picture shows the optional waste
container.

135 | 212
9.5.11 Power Sockets
Check the power sockets
Task Check the power sockets of the CrimpCenter.

Unit Entire machine
Duration -
Interval -
If one of the tests is negative, immediately contact the Schleuniger service.
WARNING
Qualified personnel

Task
1. Under certain circumstances one or
more optional power sockets are instal-
led beneath the wire intake.
1.▹ Each power socket must not have
any damages and must have a prop-
er seating.
2.▹ Check the power socket according
to DGUV-V3.
2. 1.▹ Check further power sockets on oth-
er parts of the machine, if present.
As an example the picture shows a pow-
er socket on the back bottom side of the
operator column.
Representation CrimpCenter 36 S)

137 | 212
9.6 MAINTENANCE SHEET - CHECK MACHINE
Checking complete machine
Task Check the complete machine and record result.

Unit Entire machine
Interval Yearly
Within the scope of preventive maintenance the CrimpCenter has to be checked for techni-
cal intactness and completeness.
Only proper machines are safe!
Record the result!
The maintenance interval depends on the use of the machine, but has to be executed at
least once a year.
WARNING
Qualified personnel

9.7 MAINTENANCE SHEET - SURFACE CLEANING AND PREVENTION
Entire machine
Task Cleaning ans maintaining surfaces

Unit Entire machine
Interval Weekly
Support tools See below
Parts See below
DANGER
Dangerous line voltage!
Before cleaning always switch off the main switch and unplug the
machine from the mains.
Disregarding may lead to serious injury or death.
DANGER
Risk of injury!
You may suffer serious injuries, if the machine is switched on acciden-
tally!
■ Put the main switch in position "OFF"!
■ Protect the machine against reactivation
■ Take appropriate measures to ensure, that only you can reactivate
the machine.
■ Affix a warning sign: "Do not switch on the Machine!"

139 | 212
NOTICE
Caution, property damage!
Observe the following points when cleaning the machine.
Disregard may lead to damage to property:
■ Remove impurities, deposits and lubricant residues from the interi-
or of the machine using appropriate cleaning agents.
Never use strong agents.
■ Clean the plastic surfaces of the safety cover only with solvent-free
no-fuzzing cloths.
Do not use cleaning powder.
■ Remove carrier strip splits, wire or insulation leftovers with a vac-
uum cleaner and do not blow them off with compressed air.
■ Do not use any sharp-edged objects when cleaning the machine.
■ The surface of the platform is not sealed against liquids!
Do not use loose liquids but only with a cloth for cleaning!
■ Do not use high pressure cleaner, which can damage the Crimp-
Center.
Schleuniger recommends observing the following cleaning and care instruction to guaran-
tee continued high processing quality.
■ The cleaning interval depends on the type of material produced and the frequency of
operation.
■ The area of the blades, the wire guides and the conveyor belts should be free of waste
material in order to ensure precise processing results.
■ Dirt and talcum residues may affect the functioning of the machine. The machine has
to be checked and if necessary be cleaned.
NOTICE
Hand perspiration!
Please be sure that any surface that is frequently touched or leaned on
is cleaned frequently!
Perspiration, e.g. from hands is very aggressive.

9.7.1 Touch Screen
Cleaning the touch screen
Duration -
Interval -
Parts ■ Microfiber cloth
■ clean water
1.▹ Lightly moisten the microfiber cloth.

2.▹ It is recommend to observe the cleaning and care instructions of the monitor manufac-
turer!
Example
■ Touch screen surface

141 | 212
9.7.2 PET - Surfaces
Cleaning PET-surfaces
Duration -
Interval -
Parts ■ Microfiber clothes (minimum metal parts)
■ Glass cleaner
1.▹ Wet the cloth with the cleaner generously and clean the surface,
2.▹ Dry the surface with a dry cloth.
Example
■ CrimpCenter safety cover

■ Disk at the wire intake

9.7.3 Plastic / Rubber / Eladur
Cleaning plastic, rubber and Eladur
Duration -
Interval -
1.▹ No cleaning!

143 | 212
9.7.4 Steel Surfaces
Cleaning steel surfaces - stainless steel (V2A)
Duration -
Interval -
Parts ■ Lint-free cloth
■ Stainless steel cleaner
■ WD40 spray oil
1.▹ Clean the surface with the stainless steel cleaner.

2.▹ Afterwards rub the surface with an oiled cloth.
Example
■ Stainless steel parts of the cable tray

Cleaning steel surfaces - crude steel (not gliding)
Duration -
Interval -
■ WD40 spray oil
1.▹ Rub the surface with an oiled cloth.
Example
■ Rolls of the straightening unit

145 | 212
Cleaning steel surfaces - crude steel (guide rails)
Duration -
Interval -
Parts ■ Suitable lubricant (e.g. Castrol LMX grease)
1.▹ Check the linear guides for impurities and deposits.

2.▹ Clean the guide rails with a cloth and slightly oil them with the lubricant if necessary.
3.▹ Make sure that no lubricant is applied to other areas, such as belts or electric parts.
4.▹ Remove excessive or dripping lubricant with an absorbent cloth.
Example
■ Guide rails of the swivel arms

■ UniCrimp 221/222 guide rails

Cleaning steel surfaces - nitrified steel
Duration -
Interval -
■ WD40 spray oil
Example
■ Cutter blocks (1)

147 | 212
Example
■ Wire guides (2)

■ Locking disk on the PreFeeder 60

9.7.8 Zinc Coated Surfaces
Cleaning zinc coated surfaces
Duration -
Interval -
■ Glass cleaner
■ WD40 spray oil
1.▹ Wet cloth with a glass cleaner and clean surface.

Example
■ Support of the swivel arm side 1
of a CrimpCenter 36 S

149 | 212
9.7.9 Aluminum Surfaces
Cleaning aluminum surfaces
Duration -
Interval -
■ Glass cleaner
■ WD40 spray oil

Example
■ Base plate UniCrimp 221/222
■ Base plate CrimpCenter

9.7.10 Powdered / Painted Surfaces
Cleaning / repairing of powdered / painted surfaces
Duration -
Interval -
■ Glass cleaner
■ WD40 spray oil
■ Paint stick

2.▹ Remove damages of the surface like scratches with the paint stick if necessary.
3.▹ Wait until the paint is dry.
Example
■ Cover of the swivel arm

■ Surface of the machine base frame

151 | 212
9.7.11 Tinning Station / Surrounding Parts
Cleaning tinning station and surrounding sheets and parts
Duration -
Interval Daily prior to start with work
■ WD40 spray oil
1.▹ Clean the outside of the flux tank, the tinning station and surrounding parts in conformi-
ty with the Flux manufacturer´s instructions.
2.▹ Clean the metal surfaces with an oil saturated cloth.
3.▹ Clean other surfaces with an oil saturated cloth.

9.8 MAINTENANCE SHEET - LUBRICATE GUIDE RAILS
Lubricate the guide rails
Task Lubricate the guide rails

Unit Cutting and stripping unit - guide rails
Interval Yearly
Parts ■ Suitable lubricant (e.g. Castrol LMX grease)
Check yearly and lubricate if necessary.
DANGER
Risk of injury!
tally!
the machine.

153 | 212
Task
1.▹ Use the grease gun at the highligh-
ted grease fittings.

9.9 MAINTENANCE SHEET - CLEANING THE CUTTER BLOCKS
Cleaning cutter blocks and surrounding parts
Task Check the cutter blocks and the surrounding parts for impurities
and wire and insulation leavings.
Unit Cutting and stripping unit - cutter blocks
Interval Weekly
Parts ■ Brush
■ soft brush
DANGER
Risk of injury!
tally!
the machine.
NOTICE
Observe the following points when cleaning the machine.
Disregard may lead to damage to property:
■ Do not use any sharp-edged objects when cleaning the machine.

155 | 212
Example
1.▹ Check the cutter blocks and the sur-
rounding parts for impurities and
wire and insulation leavings.
2.▹ Remove them with a soft brush or
vacuum them.

9.10 MAINTENANCE SHEET - EXCHANGING BLADE
Blade change
Task Remove cutter blocks, exchange blades, mount cutter blocks

Unit Cutter blocks - cutting blades, V-stripping blades and reject con-
tact blades
Interval Individual
Parts ■ Allen wrench 4 mm
DANGER
Risk of injury!
tally!
the machine.
DANGER
Risk of injury!
You may injure seriously when the protective equipment is insufficient.
For works on the blades and the cutter blocks wear cut resistant
gloves, when the safety cover is open!
The blades are very sharp and are not protected!
There is a risk of being cut!
Exchanging cutting and stripping blades
Task
1. To replace the blades, the cutter blocks
have to be removed.
We recommend moving the cutter
blocks completely apart by turning the
belt on the motor.
1.▹ Remove the highlighted cylinder
head screw at the bottom cutter
block.
2.▹ After removing the screw the cutter
block can be taken out.

157 | 212
Task
2. 1.▹ Remove the highlighted screw at the
upper cutter block.
2.▹ After removing the screw the cutter
block can be taken out.
Attention:
Remember the way the blades are
assembled!
Each blade has a front and a back side!
See also next picture.
3. Stacking arrangement
The schematic view shows the mounting
direction and the order of the cutting
Wire feed and stripping blades
(in the picture yellow drawings).
1.▹ Remove the cylinder head screws on
the cutter blocks and exchange the
existing blades by new ones.
2.▹ Fix the blades with the cylinder head
screws and mount the blocks on
their support.
After mounting the blocks check that
the blades are installed in the correct
direction.
1.▹ Therefore move the cutter blocks
manually towards each other by
turning the belt on the top of the
cutting and stripping unit.
Replacing the reject contact blades
Task
1. Before replacing the blades, pull the
conveyor belt approx. 30 cm back.
1.▹ Remove the safety screw and pull
the conveyor belt back.
Attention:
Take care that not pneumatic tubes or
cables get damaged when pulling back
the conveyor belt.

Task
2. The top reject contact blade is fixed with
a cylinder head screw on the backside of
the cutter block.
1.▹ To replace the blade turn out the
screw,
2.▹ remove the existing blade
3.▹ and mount the new reject contact
blade.
3. The bottom reject contact blade is fixed

with a cylinder head screw on the back-
side of the cutter block.
1.▹ To replace the blade turn out the
screw,
2.▹ remove the existing blade
3.▹ and mount the new reject contact
blade.
1.▹ Push the conveyor belt towards the
machine
2.▹ and secure it with the screw.

159 | 212
9.11 MAINTENANCE SHEET - REFERENCE INITIAL POSITION
Reference initial position - Swivel arm side 1 and 2
Task Selecting the way of referencing, referencing swivel arm side 1 and
2
Unit Cutting and stripping unit and swivel arm side 1 and 2
Interval Individual
Personnel qualifica- "2.10 Personnel qualification (Page 23)"
tion
Protective equip- "2.11 Personal protective equipment (Page 26)"
ment
■ Allen wrench 6 mm
■ Setup gauge - cutting unit
Select the existing setup gauge
Task
1. The referencing of the machine is con-
trolled by the EASY software.
2.▹ Make sure that the middle of the
wire at the guide tube of the swivel
strip-in and at the gripper side 2 is
exactly 270 mm above the platform.
3.▹ Push the pictured Machine menu
buttons in sequence.
2. 1.▹ Click the button "Referencing".

Task
3. Before the referencing starts, select
the setup gauge you will use.
The referencing can be executed with
the "Setup gauge with lever" or with the
"Setup gauge without lever".
Please select the gauge you will use for
referencing.
Notice:
It is important to select the correct setup
gauge, because the work flow varies!
Setup gauge with lever Setup gauge without lever
Article number 431 625 Article number 50000 133 673

161 | 212
Referencing with the setup gauge with lever
Task
You will use the pictured setup gauge
for referencing.
1.▹ Select the setup gauge in the selec-

tion window.
Sometimes the machine switches off the control voltage automatically. This happens for
safety reasons.
The following dialogue will guide you through the referencing. Follow the instructions. They
will be explained on the next pages:
Referencing with the setup gauge with lever
Task
"Instruction" shows the text on the screen with the number of the step in brackets.
These numbers you will find at the top right corner of the window.
"Task" describes the work steps to do.

Task
1. Instruction (1/26)
"Please switch on the control voltage.
The gripper side 2 closes."
Task:
The gripper side 2 will automatically
close.
"Please remove the wire."
Task:
1.▹ Remove the wire from the machine.
"Open the cutting unit manually, if nee-
ded."
Task:
If the cutting unit is not completely
opened, move it manually.
1.▹ Therefore turn the belt pulley in the
direction of the arrow.
"Move the swivel and stripping unit side
1 manually out of operating area."
Task:
1.▹ Move the swivel arms side 1 and 2
manually out of the operating area
around the cutting and stripping
unit to reach the cutter blocks easier.

163 | 212
Task
"Remove the lower cutter block."
Task:
1.▹ Unscrew the cylinder head screw
and the washer
2.▹ and remove the cutter block.
"Remove the upper cutter block."
Task:
and the washer
"Clean the contact surfaces of the cutter
block support."
Task:
1.▹ Clean the contact surfaces so that
the setup gauge bears exactly on
them.
2.▹ Clean these surfaces.
"Get the setup gauge and clean it if nee-
ded."
Task:
1.▹ Get the pictured setup gauge and
clean its contact surfaces, too.

Task
"Place the setup gauge in the upper sec-
tion and fix it with the cylinder head
screw."
Task:
1.▹ Place the setup gauge in the upper
section
2.▹ and fix it with the cylinder head
screw and the washer.
3.▹ Tighten the screw.
"Close the cutter onto the setup gauge
by turning the belt."
Task:
1.▹ Close the cutting unit onto the setup
gauge completely by turning the
belt manually in the direction of the
arrow.

"Fix the setup gauge to the lower cutter
block support."
Task
1.▹ Fix the setup gauge with the cylin-
der head screw to the lower cutter
block support.

"Open the calibration lever of the setup
gauge."
Task
1.▹ Open the calibration lever of the set-
up gauge by moving it in the direc-
tion of the arrow.

165 | 212
Task
"Move the swivel arm side 1 against the
setup gauge.
Attention:
Do not use long guide tubes."
Task:
1.▹ Move the swivel arm side 1 to the
setup gauge as pictured.
Do not use long guide tubes. There is
a risk of collision.
"Fix the swivel arm side 1 with the cali-
bration lever."
Task:
1.▹ Close the calibration lever of the set-
up gauge by moving it in the direc-
tion of the arrow.
2.▹ The lever has to be moved until the
swivel arm has no more play.

"Switch-off the compressed air by clos-
ing the blocking valve of the gripper side
1."
Task:
1.▹ Close the blocking valve of the grip-
per side 2.

"Align the gripper side 2 to the pin."
Task:
1.▹ Close the side 2 gripper around the
pin of the setup gauge.

Task
"Move and hold the gripper side 2
towards the setup gauge as far as it goes
and switch on the compressed air of side
2."
Task:
1.▹ Move the gripper side 2 as close as
possible to the setup gauge.
2.▹ Open the blocking valve of the grip-
per side 2.
Notice:
The gripper may only grip the pin.
1.▹ Push it towards the setup gauge as
far as possible.

Take current motor position as "0" posi-
tion for the cutter head!"
Task:
1.▹ Switch on the control voltage on the
operator column.
Instruction
"If the safety cover is open press the con-
firm button as long as all movements are
executed."
Task:
Because the safety cover is open for ref-
erencing the confirm button has to be
pushed when the machine executes
movements.
1.▹ In any case hold the confirm button
as long as the machine moves.
If the button will be released to early the
referencing will be aborted and has to
be restarted.

167 | 212
Task
"Release the calibration lever and move
both swivel arms from the operating
area."
Task:
1.▹ Open the calibration lever by sliding
it in the direction of the arrow.
2.▹ Afterwards move both swivel arms
from the operation area to reach the
cutter block easier.
"Remove the lower cylinder head screw
of the setup gauge."
Task:
1.▹ Remove the cylinder head screw.

"Open the cutting unit manually."
Task:
1.▹ Open the cutting unit by moving the
belt in the direction of the arrow.

"Unscrew the upper cylinder head screw
and remove the setup gauge and put it
to the accessories."
Task:
and the washer
2.▹ and remove the setup gauge.

Task
The machine will move to the saved
positions and will be calibrated."
Task:
1.▹ Switch on control voltage.
The machine will move automatically to
complete the calibration.
Afterwards the control voltage switches
off automatically.
Instruction
executed."
Task:
movements.
be restarted.
"Open the cutter head if needed."
Task:

169 | 212
Task
"Mount the upper cutter block."
Task:
1.▹ Mount the upper cutter block
2.▹ and fix it with the highlighted cylin-
der head screw and the washer.

"Mount the lower cutter block."
Task:
1.▹ Mount the lower cutter block
27. Instruction (End)

"Referencing completed."
Task:
1.▹ Confirm message.
The referencing is completed.

Referencing with the setup gauge without lever
Task
You will use the pictured setup gauge
for referencing.
1.▹ Select the setup gauge in the selec-

tion window.
Sometimes the machine switches off the control voltage automatically. This happens for
safety reasons.
The following dialogue will guide you through the referencing. Follow the instructions. They
will be explained on the next pages:
Referencing with the setup gauge without lever
Task

171 | 212
Task
The gripper side 2 closes."
Task:
The gripper side 2 will automatically
close.
Task:
1.▹ Remove the wire from the machine.
"Open the cutting unit manually, if nee-
ded."
Task:
If the cutting unit is not completely
opened, move it manually.
1.▹ Therefore turn the belt pulley in the
direction of the arrow.
"Move the swivel and stripping unit side
1 manually out of operating area."
Task:

Task
"Remove the lower cutter block."
Task:
and the washer
"Remove the upper cutter block."
Task:
and the washer
"Clean the contact surfaces of the cutter
block support."
Task:
1.▹ Clean the contact surfaces so that
the setup gauge bears exactly on
them.
2.▹ Clean these surfaces, too.
"Get the setup gauge and clean it if nee-
ded."
Task:
1.▹ Get the pictured setup gauge and
clean its contact surfaces, too.

173 | 212
Task
"Place the setup gauge in the upper sec-
tion and fix it with the cylinder head
screw."
Task:
1.▹ Place the setup gauge in the upper
section
2.▹ and fix it with the cylinder head
screw and the washer.
"Close the cutter onto the setup gauge
by turning the belt."
Task:
1.▹ Close the cutting unit onto the setup
gauge completely by turning the
belt manually in the direction of the
arrow.

"Fix the setup gauge to the lower cutter
block support."
Task
1.▹ Fix the setup gauge with the cylin-
der head screw to the lower cutter
block support.

"Move the swivel arm side 1 against the
setup gauge.
Attention:
Do not use long guide tubes."
Task:
1.▹ Move the swivel arm side 1 to the
setup gauge as pictured.
Do not use long guide tubes. There is
a risk of collision.

Task
"Switch-off the compressed air by clos-
ing the blocking valve of the gripper side
1."
Task:
1.▹ Close the blocking valve of the grip-
per side 2.

"Align the gripper side 2 to the pin."
Task:
1.▹ Close the side 2 gripper around the
pin of the setup gauge.

"Move and hold the gripper side 2
towards the setup gauge as far as it goes
and switch on the compressed air of side
2."
Task:
1.▹ Move the gripper side 2 as close as
possible to the setup gauge.
2.▹ Open the blocking valve of the grip-
per side 2.
Notice:
The gripper may only grip the pin.
1.▹ Push it towards the setup gauge as
far as possible.

175 | 212
Task
Take current motor position as "0" posi-
tion for the cutter head!"
Task:
1.▹ Switch on the control voltage on the
operator column.
Instruction
executed."
Task:
movements.
be restarted.
"Move both swivel arms from the opera-
tion area."
Task:

"Remove the lower cylinder head screw
of the setup gauge."
Task:
1.▹ Remove the cylinder head screw.

Task
"Open the cutting unit manually."
Task:

"Unscrew the upper cylinder head screw
and remove the setup gauge and put it
to the accessories."
Task:
and the washer
2.▹ and remove the setup gauge.

The machine will move to the saved
positions and will be calibrated."
Task:
1.▹ Switch on control voltage.
The machine will move automatically to
complete the calibration.
Afterwards the control voltage switches
off automatically.

177 | 212
Task
Instruction
executed."
Task:
movements.
be restarted.
"Open the cutter head if needed."
Task:

"Mount the upper cutter block."
Task:
1.▹ Mount the upper cutter block

Task
"Mount the lower cutter block."
Task:
1.▹ Mount the lower cutter block
25. Instruction (End)

"Referencing completed."
Task:
1.▹ Confirm message.
The referencing is completed.

179 | 212
9.12 MAINTENANCE SHEET - REFERENCING CRIMPING STATION SIDE 1
Referencing initial position - Swivel arm side 1 and crimping station
Task Referencing of the swivel arm side 1

Unit Swivel arm side 1 and crimping station
Interval Individual
Parts ■ Setup gauge (article number 50000 133 489)
■ Setting pin (Centering pin, article number 50000 586 799)
■ Caliper rule
Task
wire at the guide tube of the swivel
strip-in is exactly 270 mm above the
platform.
The crimping station has to be loaded.
2. 1.▹ Click the highlighted register.
Attention:
The outlet guide 5.0 has to be mounted
on the swivel arm side 1.

Task
3. 1.▹ Switch on the control voltage and
click on the entry field "Angle".
The following dialogue will guide you
through the referencing.
1.▹ Follow the instructions.
They will be explained on the next
pages:
4. Instruction
Task:
1.▹ Make sure that the wire is removed.
5. Instruction
"Switch off compressed air and insert
setting pin (long) in the gripper manual-
ly."
Task:
1.▹ Switch off the air pressure supply on
the main valve.
Task:
1.▹ Set the setting pin (centering pin) as
far as it goes in the outlet guide.

181 | 212
Task
Task:
1.▹ Place the referencing tool in the hole
of the applicator support of the
crimping station.
6. Instruction
"Move the stripping and swivel units in
the safe position."
Task:
1.▹ Move the swivel arm side 2 in front
of the crimping station.
The centering pin should be in the mid-
dle of the referencing tool.

Task
7. Instruction
"Activate the machine, switch on com-
pressed air and adjust stripping and
swivel unit to the target in the following
user menu."
Task:
1.▹ Move the centering pin with the
1 1
arrow buttons exactly to the middle
of the referencing tool.

183 | 212
Task
Task:
1.▹ Measure the distance of the rear
edge of the referencing tool and the
front edge of the outlet guide with a
caliper rule.
Set point is 41 mm
Task:
1.▹ Enter the determined value with the
arrow buttons (1) top / bottom.
1
2.▹ Save position.
The referencing of the station on
side 1 is finished.
1

9.13 MAINTENANCE SHEET - REFERENCING CRIMPING STATION SIDE 2
Referencing initial position - Swivel arm side 2 and crimping station
Task Referencing of the swivel arm side 2

Unit Swivel arm side 2 and crimping station
Interval Individual
Parts ■ Setup gauge (article number 50000 133 489)
■ Setting pin (Centering pin, article number 50000 586 799)
Task
wire at the gripper side 2 is exactly
270 mm above the platform.
The crimping station has to be loaded.
2. 1.▹ Click the highlighted register.

185 | 212
Task
3. 1.▹ Switch on the control voltage and
click on the entry field "Angle".
The following dialogue will guide you
through the referencing.
1.▹ Follow the instructions.
They will be explained on the next
pages:
4. Instruction
Task:
1.▹ Make sure that the wire is removed.
5. Instruction
"Switch off compressed air and insert
setting pin (long) in the gripper manual-
ly."
Task:
1.▹ Switch on the air pressure supply on
the main valve.
Task:
1.▹ Set the setting pin (centering pin as
far as it goes in the gripper side 2.

Task
Task:
1.▹ Place the referencing tool in the hole
of the applicator support of the
crimping station.
6. Instruction
"Move the stripping and swivel units in
the safe position."
Task:
1.▹ Move the swivel strip-in in front of
the crimping station.
The centering pin should be in the mid-
dle of the referencing tool.

187 | 212
Task
7. Instruction
"Activate the machine, switch on com-
pressed air and adjust stripping and
swivel unit to the target in the following
user menu."
Task:
1.▹ Move the centering pin with the
1 1
arrow buttons exactly to the middle
of the referencing tool.

Task
Task:
1.▹ Measure the distance of the rear
edge of the setup gauge and the
front edge of the gripper with a cali-
per rule.
Set point is 50 mm
Task:
1.▹ Adjust the distance of the gripper
and the setup gauge with the arrow
1
buttons (1) top / bottom to 50 mm.
2.▹ Save position.
The referencing of the station on
1 side 2 is finished.

189 | 212
9.14 MAINTENANCE SHEET - EXCHANGE FEEDING BELTS
Exchange feeding belts and check belt tension.
Task Remove feeding belts, exchange feeding belts and mount feeding
belts, check feeding belt tension
Unit Swivel strip-in side 1 feeding belts
Interval Individual
tion
ment
■ optional Belt tensioner (article number 423 260)
■ optional testing gauge (Lever, article number 50000 587 102)
DANGER
Risk of injury!
tally!
the machine.
Task
1. 1.▹ Open the feeding belts

Task
2. 1.▹ Remove the guide tube in front of
the feeding belts.
3. Remove the guide tubes behind the

feeding belts.
1.▹ Therefore loosen the lever of the
quick change holder
2.▹ and remove the tube.
4. 1.▹ Loosen the 2 cylinder head screws of

the pulleys (1).
1 1
Do not turn them out.
1.▹ Remove the cylinder head screws (2)
2.▹ and the flanged disks (2).
Now the belts can be removed and
replaced by new ones.
1.▹ Mount the flanged disks and the cyl-
inder head screws (2).
2
2

191 | 212
Task
5. 1.▹ Place the optional belt tensioner
(article number 423 260) between
the pulleys.
2.▹ Turn the hexagonal bolt between
the blocks until the belts are ten-
sioned.
3.▹ Tighten the cylinder head screws (in
the picture left).
4.▹ Remove the belt tensioner.
6. The optional belt tensioner (article num-

ber 50000 587 102) is needed to check
the belt tension.
1.▹ Put the lever over the belt.
The belt should be aligned at the under-
side.
7. 1.▹ Hang up a spring balance in the eye

of the lever
2.▹ and pull the gauge until it reaches a
45° pitch.
Now the spring balance should show a
value of 4.5 N (+/- 0.5 N).
1.▹ If necessary adjust the tension of the
belts again.
Both belts have to be checked.
8. The belt tension can also be measured
with an electronic belt tension meter.
(article number 431 497).
This method is more accurate.
1.▹ Place the belt tension meter at the
belt as shown in the picture and
strike against the belt.
The correct value is
210 Hz (+/- 10 Hz).

9.15 MAINTENANCE SHEET - DUMP CONDENSATE
Dump condensate
Task Check for collected condensate and dump the water if needed
Unit Pneumatic unit - condensate drain
Duration approx 1 min.
Interval Monthly
Parts ■ Absorbent cloth
DANGER
Risk of injury!
tally!
■ The pneumatic system is pressurized.
■ Working on pressurized system will cause serious accidents.
Task
1. 1.▹ Check the collected condensate.
2.▹ Dump the water if necessary.
Put an absorbent cloth under the
drain valve and press the orange
button.

193 | 212
9.16 MAINTENANCE SHEET - CLEAN FILTER CARTRIDGE
Clean filter
Task Remove filter cartridge, clean filter and mount filter cartridge
Unit Pneumatic unit - clean filter
Interval Yearly
DANGER
Risk of injury!
tally!
■ The pneumatic system is pressurized.
■ Working on pressurized system can cause serious accidents.

Task
1. 1.▹ Dump existing condensate if needed
See "9.15 Dump condensate
(Page 193)"
2.▹ Close the main valve.
1
3.▹ Remove the 2 cylinder head screws
(1) with a 4 mm Allen wrench.
2. 1.▹ Pull the black lever (1) down and

turn the cylinder clockwise.
(approx. eight rotations)
2.▹ Pull the cylinder downwards.
3.▹ Remove the cartridge and clean it.
4.▹ Insert the cartridge.
5.▹ Place the cylinder and turn it coun-
terclockwise.
The black lever automatically snaps
in.
6.▹ Mount the unit with the 2 cylinder
head screws.

195 | 212
9.17 MAINTENANCE SHEET - FILTER ELEMENTS
Check and exchange filter elements
Task Check the filter elements of the fans in the control cabinet, exchange
the filter elements of the fans of the control cabinet
Unit Control cabinet - Filter elements
Interval Weekly
tion
ment
Parts ■ Slotted screwdriver
■ Replacement filter elements for filter fan (article number 426 908)
The machine is equipped with air filters on the fan exhausts to prevent dust and other parti-
cles from contaminating the machine.
The air filters should be checked periodically, depending on the usage and if required be
replaced, to prevent the machine to overheat and to avoid faults.
NOTICE
Change interval!
There are no fixed rules how often the filters have to be changed.
The interval depends on the operating environment where the
machine is operated.
NOTICE
Only use original Schleuniger filters.
Using wrong filters may overheat the machine or damage it due to
dust penetrating into.
Never operate the machine without filters.
Dust is depositing and may cause short circuit and creeping current in
the electronics.
Necessarily replace filters when the machine warms up too much.
DANGER
Risk of injury!
tally!
the machine.

Task
1. There are intakes for the supply air and
the exhaust air on the control cabinet.
Behind the grids filter elements are
mounted, which are cleaning the cool-
ing air.
■ They have to be cleaned weekly.
If necessary exchange the elements with
new ones
(filter element for filter,
article number 426 908)
■ You will find the filter for the supply
air beneath the operator panel.
2. ■ The two filters for the exhaust air are
placed beneath the wire intake.
■ The grids will be opened from the

outside.
■ There is an opening at the bottom
edge of each grill.
3. 1.▹ Insert a small slotted screwdriver

into the opening and lift off the grill.

197 | 212
Task
4. 1.▹ Simultaneously grip the grill at the
bottom and pull it forward.
5. Now remove the grill.

1.▹ Remove the filter element
2.▹ and clean it.
For reassembly, follow the steps in
reversed order.

9.18 MAINTENANCE SHEET - CHECK CONVEYOR BELT
Check conveyor belt
Task Check the conveyor belt for damages and wearing

Unit Conveyor Belt
Interval Weekly
1.▹ Check the conveyor belt for damages and wearing.

199 | 212
10. Spare parts
SPARE PARTS
WARNING
Spare parts may only be mounted by trained personnel.
(Schleuniger personnel, qualified technical personnel on site)
Improper handling may lead to injury.
For original Schleuniger spare parts see „Parts List“.

11. Decommissioning / disposal
DECOMMISSIONING / DISPOSAL
CAUTION
The product must only be decommissioned and disposed by accord-
ingly trained personnel (Schleuniger personnel, qualified technical per-
sonnel on site).
Disregarding may lead to injury.
DANGER
Risk of injury
There is a danger of electric shock!
Even after the machine has been disconnected from the power supply
wires are energized.
Observe the warning signs "Warning of dangerous voltage"!
11.1 DECOMMISSIONING
To decommission the machine proceed as follows:
2.▹ Click the button "System" in the top right corner of the touch screen.
Select in the following dialogues "Quit" and then "Shut down CrimpCenter".
3.▹ As far as the request to switch off the CrimpCenter appears on the screen, switch off the
main switch.
Before switching on the CrimpCenter again wait at least 5 minutes.
4.▹ Unplug the machine from the mains.
5.▹ Interrupt the air pressure supply and remove the air hose.
6.▹ Remove all interface cables connected to the peripheral devices and put them aside.
WARNING
Removing the Conveyor Belt!
Attention:
Prior to removing the conveyor belt the supplies must be disconnec-
ted!
■ Never tear off cables and pneumatic hoses.
Always disconnect the cables and tubes appropriately.
■ Prior to release them, label the components and their position in
relation to one another.
■ Observe the instructions for external component units provided in
the manual of the manufacturer.
■ Observe the separate manuals of the processing stations and
options you are going to install, connect or disassemble.

201 | 212
11. Decommissioning / disposal
11.2 DISASSEMBLY / DISPOSAL

NOTICE
Recycling according to legal regulations!
Disassemble the machine appropriately.
See also chapter "11 Decommissioning / disposal (Page 201)".
Dispose of the disassembled parts according to the local legal require-
ments.
Schleuniger machines mainly consist of the following materials:
Material Disposal
Aluminum Scrap metal
Steel Scrap metal
Other metal Scrap metal
Electric parts Electronic waste
Plastics Recycling
NOTICE
Recycle the battery according to regulations!
The battery in this product contains heavy metals which are harmful to
the environment and is therefore hazardous waste.
Recycle the battery!

12. Overview of symbols
OVERVIEW OF SYMBOLS
The following table shows all stickers used on the CrimpCenter 36 S.
Depending on the equipment, some stickers may be not on the specific machine.
Symbol Function
Shut off valve
The air supply for the complete machine will be switched on or off with the
shut off valve.
See also chapter "8.1 Starting Conditions (Page 89)"
Main pressure regulator
The air pressure for the complete machine will be adjusted at the main pres-
sure regulator.
See also chapter "8.1 Starting Conditions (Page 89)".
Water drain
The condensate can be drawn at the water drain.
See also chapter "9.15 Dump condensate (Page 193)".
Wire feed
Adjust the contact pressure of the feeding belts on the swivel arm side 1
with this pressure regulator.
See also chapter "8.9 Adjust the Contact Pressure of the Wire Feed (Page 105)".
Gripper pressure
Adjust the gripper pressure for the gripper side 2 with this pressure regula-
tor.
See also chapter "8.10 Adjust the Clamping Force of the Gripper (Page 106)".
Gripper pressure - Double gripper
Adjust the gripper pressure for the gripper side 2 when a double gripper is
activated (optional).
See also chapter "8.10 Adjust the Clamping Force of the Gripper (Page 106)".
Open / close wire feed
The feeding belts will be opened or closed with this toggle switch.
See also chapter "8.8 Insert Wire (Page 100)".
Safety cover
The safety cover will be opened or closed with these two pushbuttons.
See also chapter "6.1 Safety Cover - Pushbutton and Confirm Button (Page 68)".
Lifting Points
This label marks the positions where the machine has to be lifted with a fork-
lift.
See also chapter "3.4 Lifting Points (Page 30)".

203 | 212
Index
Symbol Function
Conveyor Belt
This label shows the designated rotation direction of the conveyor belt.
Confirm Buttons
This is a confirm button.
See also chapter "6.1 Safety Cover - Pushbutton and Confirm Button (Page 68)".
Feed wire
The wire will be fed by pushing this button.
See also chapter "8.8 Insert Wire (Page 100)".

Index
INDEX
A I
Abbreviations 10 Info 10
Accident prevention regulations 8 Intended application 19
Activity direction 10 Interface connection cable 16
Assemblies 41
L
B Legend 10
Battery 202 Liability for damage 11
Blades 66 Line frequency 36
Blocked wire/cable 18 Lubricating grease 16
C M
Cleaning intervals 111 Machine description 13
Clockwise 11 Maintenance 111
Commands 10 Maintenance table 111
Compressed air 36 Mark-up 10
Conveyor belt 199 Measures 10, 33
Cross reference 10
Cutter block 157 N
Noise level 18
D
Danger banner 18 O
Dangerous zones 73 Operating company 23
Disposal 10, 202 Operating personnel 9
Double gripper module 106 Operator personnel 24
Over heating 35
E Overview 10
Earth conductor 16
EASY 39 P
EASY ProductionServer 39 Packaging 31
EASY Quality Center 40 Personnel older than 14 years 23
Emergency stop circuit 16 PET 142
Emergency stop link 27 Power supply 36
Emergency stop switch 71 Product name 10
Protective equipment 26
F
Fan exhaust 35 Q
Figure 10 Qualified personnel 24
Foreseeable misuse 20
R
G Rating plate 38
Guidelines 11 Rating Plate 38
Recycle 10
H Registered trademarks 12
Hotline 110 Residual risks 18
Result 10

205 | 212
Index
S Talk 18
Safety barrier 27 Technical specialist 24
Safety cover 27 Third parties 12
Safety devices 27 Time intervals 111
Safety regulations 8 Tip 10
Safety Regulations 16 Topic 10
Schleuniger distributor 110 Trademarks 12
Schleuniger original fan filter 196 Transport fixations 30
Screen titles 10
Service technician 23 W
Software version 110 Warning notice 15
Standards 11 Weight 33
Straightening unit 100 Windows® 12
Symbols 10 Wire guide 140
Wire type 110
T
Talcum 140

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207 | 212
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209 | 212
13. Wiring Diagrams
WIRING DIAGRAMS

0 1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
F F
Date 18.01.16 Unit Project number
work G.Woitke CC36S 434231
Field
check Drawing number sheet 1
Wiring diagram complete
Status rev. Date name norm DIN 81346 created from 455845 of 56
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
Up from August 2015 the version on sheet 2 is

!!! INVALID !!!
please see notification of change 041-15
in the future always with transformer, please see sheet 3
B B
-W-Q2
br sw gr bl gn-ge ÖLFLEX 5G2,5
1
C C
2 4 6
.
-Q1 -X1
32 A 1 3 5 PE
-4
br sw gr gn-ge ÖLFLEX 5G2,5
. L1'
. L2'
. L3' . PE
D Load ground strap D

-Z1 L1 L1 6.0
Line L2 L2 6.0
. . . . L3 L3 6.0
L1 L2 L3 PE Attention
. N 6.0
.
High voltage at clamps when Mainswitch is off
-X1 N PE 6.0
L1 L2 L3 N PE
E 2,5mm² E
e.g. 3 x 400V 16A
supply 5x2,5mm²
fuse 3 x 16A
F F
Date 18.01.16 Unit supply Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A Attention A
set to 3x400V
B B
1U1
1U3
1U4
1U5
1U6
1U7
1U2
1V1
1V3
1V4
1V5
1V6
1V7
1V2
1W1
1W3
1W4
1W5
1W6
1W7
1W2
-T1
1
Trafo 210V-500V
-W-Q2.
br sw gr gn-ge ÖLFLEX 5G2,5
C C
400 V
400 V
400 V
N
2 4 6
.
-X1
-Q1 -W-Q4
32 A 1 3 5 ÖLFLEX 5G2,5 br sw gr bl gn-ge
PE
-W-Q1.
br sw gr gn-ge ÖLFLEX 5G2,5 network
separate protective earth (PE) and neutral (N) system
. L1'
. L2'
. L3' . PE
D Load ground strap -X1 D

-Z1 L1 L1 /5.0
.
Line L2 L2 /5.0
.
. . . . L3 L3 /5.0
.
L1 L2 L3 PE N N /5.0
N PE
green-yellow
/5.0
E Attention Attention 2,5mm² E

brown
black
.
grey
High voltage at clamps when Mainswitch is off

Connection "N" to "PE"
must be established
3 x 400V 16A
supply 5x2,5mm²
fuse 3 x 16A
F F
Date 18.01.16 Unit supply through transformer Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
primary Connect connection
A A
1U4 1U4 - 1V5
210 V 1V4 1V4 - 1W5
1W4 1W4 - 1U5
1U3 1U3 - 1V5

230 V 1V3 1V3 - 1W5
1W3 1W3 - 1U5
1U1 1U1 - 1V5

250 V 1V1 1V1 - 1W5
B 1W1 1W1 - 1U5 B
1U4 1U4 - 1V6

380 V 1V4 1V4 - 1W6
1W4 1W4 - 1U6
exampel
supply L1 1U3 1U3 - 1V6

3 x 400 V L2 400 V 1V3 1V3 - 1W6
L3 1W3 1W3 - 1U6
C 1U1 1U1 - 1V6 C

420 V 1V1 1V1 - 1W6
1W1 1W1 - 1U6
1U4 1U4 - 1V7

440 V 1V4 1V4 - 1W7
1W4 1W4 - 1U7
1U3 1U3 - 1V7

460 V 1V3 1V3 - 1W7
1W3 1W3 - 1U7
D D
1U3 1U3 - 1V2

480 V 1V3 1V3 - 1w2
1W3 1W3 - 1U2
1U1 1U1 - 1V2

500 V 1V1 1V1 - 1w2
1W1 1W1 - 1U2
E E
secondary to cabinet
400 V L1
400 V L2 3 x 400 V
400 V L3
N N
F F
Date 18.01.16 Unit Transformer Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
L1 black
/3.8
L2 black
/3.8
L3 black
/3.8
A A
N light blue N /7.0
/3.8
PE green-yellow PE /7.0
/3.8
2,5mm² . . . . .
-F013 -F014 -F015
-F02 -F03 -X1 L1 L2 L3 N PE
C10A C16A B6A B6A B6A
option STS 1100
1,5mm² 1,5mm²
B The Terminal Board X1/4-6 B

1 3 5 1 2 1 2 3 4 5 6 and bridge
are in need
-Q2 -X1 . gr . gr . gr . gr . gr . gr retrofit
/15.2 2 4 6 -G1
. 1 2 3 3 4 5
24V DC= 2 -X1 . hbl . hbl . hbl . hbl . bl . bl

Varistor 10A - +
1 2 3 3 4 5
2 4
L4 /7.0 -X1 . . . . . .
C L5 /7.0 2,5mm² C
-F10
L6 /7.0 . .
T4A
-X300
2,5mm² . 14a 1d
-X19 -X13 -X14 -X15
L7 /10.0 Mounting place
L8 /10.0 X13 = wire feeder

/13.0 X300 0V DC
230V 230V 230V 230V X14 = wire feeder

L9 /10.0 M PE (Option) (Option) (Option) X15 = operator side
D 2,5mm² D
-M02
-E1
/12.0 L+
Fan Computer
(Option)
PC
USB connections
Monitor
E battery E
Back UP
-G2
USB USV
UPS
Switch /46.2 power supply 230V AC
USB-HUB /6.4
F F
Date 18.01.16 Unit 230V AC supply Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
Wall power supply

is plugged into the UPS
USB-HUB
/5.6
extension of USB connections
USB-HUB
about HUB
B standard usb connections B
Computer on the PC
-X20 USB power point
BarcodeScanner
Touch Monitor SW patch necessary
(Option)
UPS -X23
USB power point
standard
cabinet
USB-HUB
Operator side
C C
reserve remote control (option)
-X30
USB power point
Labelprinter
SW patch necessary
(Option)
USB hub is attached in the

D vicinity from the PC D
E E
F F
Date 18.01.16 Unit USB sockets Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
L4 black L4
/5.2 /9.0
L5 black L5
/5.2 /9.0
L6 black L6
/5.2 /9.0
A A
N light blue N
/5.8
PE green-yellow PE
/5.8 /9.0
2,5mm²
-F04 -F05 -F06 -F07

C 16A C 16A C 16A C 16A light blue
gr-ge
bk
1,5mm² 2,5mm²
B B
230V AC 230V AC 230V AC 230V AC
7 8 9 10 11 12 13 14 15 16 17
-X1 . gr . gr . gr . gr . gr . gr . gr . gr . gr . gr . gr
7 8 9 10 11 12 13 14 15 16 17
-X1 . bl . bl . bl . bl . bl . bl . bl . bl . bl . bl . bl
C C
7 8 9 10 11 12 13 14 15 16 17
-X1 . . . . . . . . . . .
/8.4 -Q14.1
/8.4 -Q14.3
1 2 3
D D
station cable side 1 station 1

-X10
/8.4
/8.4
prefeeder
-Q15.2
-Q15.4
(Option)

conveyor belt reserve conveyor belt reserve

supply supply
controller T01 controller T02
motor 20 motor 21
PE
PE
L
N
L
N
E see wiring diagramm see wiring diagramm E
50000436571 50000436571
(Option) (Option)
F F
Date 18.01.16 Unit 230V distribution for stations Project number
CC36S supply
work G.Woitke 434231
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
/7.2
/7.6
-Q14.1
-Q14.3
-Q14.5
black
1,5mm²
B B
5
-Q14
/15.7
6
black
1,5mm²
C C
6
-Q15
/15.8
5
1,5mm²
D D
/7.2 -Q15.2
/7.6 -Q15.4
-Q15.6
E E
F F
Date 18.01.16 Unit 230V deactivation stations when Project number
CC36S safety cover is open
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
L4 black
/7.8
L5 black
/7.8
L6 black
/7.8
A A
PE green-yellow PE
/7.8 /10.0
2,5mm²
1 3 5
-Q5 Please remove the assemblies -Q5 and -Q3

/22.1 2 4 6 inclusive wiring, if a frequency converter
will be used.
For the operation of a frequency converter
B Varistor B
see wiring diagram 500436571 (option).
C C
1 3 5 1 3 5
-Q3 -Q3.1
2 4 6 2 4 6
2 A 2 A
-W-XM20
ÖLFLEX SY 4G0,75 1 2 3 PE
D D
-XM20 1 2 3 PE -XM21 1 2 3 PE
Varistor Varistor
U V W PE U V W PE
M M
-M20 3 -M21 3
E conveyor belt E
conveyor belt flaring
(Option)
F F
Date 18.01.16 Unit Conveyor belt controlling Project number
CC36S contactor techinque
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
L7 black
/5.2
L8 black
/5.2
L9 black
/5.2
A A
PE green-yellow
/9.8
2,5mm²
-F01
B 16A B
C C
A13-L1
A13-L2
A13-L3
A13-PE
A15-L1
A15-L2
A15-L3
A15-PE
A16-L1
A16-L2
A16-L3
A16-PE
/31.1 A11-L1
/31.1 A11-L2
/31.1 A11-L3
/31.1 A11-PE
/32.1 A12-L1
/32.1 A12-L2
/32.1 A12-L3
/32.1 A12-PE
D D
/33.1
/33.1
/33.1
/33.1
/34.1
/34.1
/34.1
/34.1
/35.1
/35.1
/35.1
/35.1
A11 A12 A13 A15 A16
ACOPOS ACOPOS ACOPOS ACOPOS ACOPOS
1016 1016 1016 1016 1016
wire feeder cutting head swivel arm 1 swivel arm 2 pull-off unit
+ haul-off 1 side 1 side 2 side 2
E E
F F
Date 18.01.16 Unit 400V distribution ACOPOS Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/5.3
A A
L+
.
clamp
-X5
-F1 -F2 -F3 -F4 -F5 -F6 -F7 -F8

B T6,3A T6,3A T6,3A T4A T4A B
2a 2a 2a 2b 2b 2a 2a 2a
2b 2b 2b 2a 2a 2b 2b 2b
/31.6 -A11-X1.14
-X301.2 . .
.
-X3 -X3
/47.6 CPU
19d 21d option

1a
/13.1 F4
/13.4 F5
C C
/14.0 F3 24V
.
-X301 1a
-A12
-A16
X501-G 24V DC side 1 side 2

D station 1, 2, 3 station 1, 2, 3 D
/14.0 X301-P 24V DC
cutting head
haul-off 2
CPU
-A11
-A13
-A15
E E
swivel arm engine 1
swivel arm engine 2

wire feeder
F F
Date 18.01.16 Unit 24V distribution Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/5.3 X300 0V DC X300 0V DC /14.0
A A
/12.3
/12.4
X300 0V DC
X300 0V DC
F4
F5
. .
B -X3 17c 20c B
. . . . . .
-X3 17b 18b 19b -X3 20b 21b 22b

. . . . . .
-X300 6d 7a 7b 3b 3c 2c
-W22.1 -W22.4
ÖLFLEX 2X1 br bl ÖLFLEX 2X1 br bl
-W22.2 -W22.5
C -W22.3 -W22.6 C
1 1
2 1 1
2 1 1
2 1 1
2 1 1
2 1 1
2
-X2.1 -X2.2 -X2.3 -X2.1.2 -X2.2.2 -X2.3.2
+ - + - + - + - + - + -
24VDC 24VDC 24VDC 24VDC 24VDC 24VDC
station 1 station 2 station 3 station 1 station 2 station 3
(Option) (Option)
D D
side 1 side 2
E E
F F
Date 18.01.16 Unit 24V voltage distribution for Project number
CC36S stations connections
Field
0 1 2 3 4 5 6 7 8
F
E
D
C
B
A
/12.2
/13.8
/12.1
Status
0
0
protection cover
F3 24V
close -S6
O1 - O6 = 1A
IO1-IO4 = 0,25A
-K16
rev.
X300 0V DC
-X3
-X301.2
Schh. schl. 30d . 13 INPUT 13 17 1b .
X301-P 24V DC
/24.3
24 VDC
DINA
Date
-X300.2
-X300.2
14 INPUT 14 GND 18 1b . 1a .
1
1
name norm
work
Date
check
-X70
15 INPUT 15 INPUT 1 1 1 1 K16/I 1 /21.0
DNSL-ZMVK 1/2
G.Woitke
18.01.16
DIN 81346
2
2
16 INPUT 16 INPUT 2 2 2 2 K16/I 2 /21.0
Unit
Field
emergency stopping
CC36S
21 Input/Output 1 INPUT 3 3 7 7 K16/I 3 /19.1
OFF
Button
3
3

22 Input/Output 2 INPUT 4 4 8 8 K16/I 4
ON
/19.2
Button
23 Input/Output 3 INPUT 5 5 9 9 K16/I 5 /20.2
4
4
24 Input/Output 4 INPUT 6 6 10 10 K16/I 6

safety switch
/20.2
Message output
safety cover status
created from
19 OUTPUT 1 INPUT 7 7 3 3 K16/I 7
/19.5 K16/O 1 /21.0
5
5
Message output
confirm button
20 OUTPUT 2 INPUT 8 8 4 4 K16/I 8
/19.6 K16/O 2 /21.0
confirm push button
Message output no
emergency stop
6
6
-Q2
25 OUTPUT 3 INPUT 9 9 5 5
/19.7 K16/O 3
/15.2 22
21
K16 safety PLC

/15.8
-Q15
/15.7
-Q14
-X301
quickstop 26 OUTPUT 4 INPUT 10 10 6 6 21 22 22 21 1d .

/35.3 -A16-X1.2
7
7
Message output main

contactor switched on Port will be left on CC36S
27 OUTPUT 5 INPUT 11 11
/23.1 K16/O 5
455845
434231
Message output
safety cover close
28 OUTPUT 6 INPUT 12 12 K16/I 12
/24.4 A1.2/E10 /22.4
Project number
Drawing number
SPS Output
8
8
of
sheet
X300 0V DC /15.0
X301-P 24V DC /23.0
56
14
protection cover close
F
E
D
C
B
A
0 1 2 3 4 5 6 7 8
A A
-K16 K1,K2//DC1: 24V/6A

DINA DC13: 24V/2A
DNSL-ZMVK 2/2 K3-K6//DC1:
DC13:
24V/6A
24V/5A
K1 K2 K3 K4 K5 K6
B B
13 14 23 24 33 34 43 44 53 54 63 64 73 74 83 84 93 94 103 104
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
29
X501-G 24V DC /24.0
-X301.2
.
.
1d
2a
3c
3d
C C
. 1a/b
-X501
/31.5 Enable 24V STO
/31.5 Enable 0V STO

24V Switch on
-X3
.
K16/73
. 29d
-X3
/19.3
D D
rt 29a
-W15.1
5
ÖLFLEX CLASSIC 100 15G0,75
X1
A1
A1
A1 A1
-Q14 -Q15
green
-YR40 -Q2 -H3

at S03 -X300.2
.
A2
A2
A2
A2 X2
15kW H4/X2 /21.8
1c
bk
-W15.1
6
. . .
-X300 4c 5c 5a
E E
/14.8 X300 0V DC X300 0V DC /22.0
24V DC connected main relay

protection cover
close 1 2
/8.4
3 4
/8.4
1 2 5 6
/5.0 /8.4
3 4 21 22
/5.0 /14.7
5 6 43 44
/5.0 /20.4
13 14 53 54
/20.6
21 22
/14.6
F F
Date 18.01.16 Unit K16 safety PLC Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
R1
B B
8
R2
INPUT 1
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
Resolver 1
RJ45_R1 B11/K17_R1
-K17 /31.3
O1,O2 = 0,25A DINA
C
O3-O7 = 1,00A DNSL-DRV resolver measuring system C
Resolver 2
B12/K17_R2 /32.3
Output 1 RJ45_R2
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
P24V
9
10
11
12
13
14
15
16
D D
-X301.2 -X16
.
.
2b
1a
3a
E E
F F
Date 18.01.16 Unit K17 resolver measuring system Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
R1
B B
8
R2
INPUT 1
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
Resolver 1
RJ45_R1 B13/K18_R1
-K18 /33.3
O1,O2 = 0,25A DINA
C
Resolver 2
Output 1 RJ45_R2 Port will be left free on CC 36 S
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
P24V
9
10
11
12
13
14
15
16
D D
-X301.2
.
3a
E E
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
R1
B B
8
R2
INPUT 1
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
Resolver 1
RJ45_R1 B15/K19_R1
-K19 /34.3
O1,O2 = 0,25A DINA
C
Resolver 2
B16/K19_R2 /35.3
Output 1 RJ45_R2
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
P24V
9
10
11
12
13
14
15
16
D D
-X301.2
.
3b
E E
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
-A1.1 -A1.1
digital output digital output
main contactor enabled controller release_ON
/49.1 -X16 /49.1
.
B A1 A2 B
2d
X11 X21
-W15.1
1
ÖLFLEX CLASSIC 100 15G0,75 3
11 13
-S02 -S03
/14.5
/14.5
/14.6
OFF 12 ON 14
C C
-W15.1
K16/O 1
K16/O 2
K16/O 3
2

/14.3 K16/I 3
/14.3 K16/I 4
/15.5 K16/73
D D
-A1.2 X23 X14 -A1.2 X21 -A1.2

E6 /51.1 E7 /51.1 E2 /51.1
protection cover_close Emergency stop relay on Emergency stop relay on

E E
digital input digital input digital input
F F
Date 18.01.16 Unit ON/OFF Button Project number
CC36S SPS Input
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
-X501 -X301
.
1b
6c
-X16
43
53
-Q14
2a
4b
/15.7
44
54
B B
-W24.2
44
54
4x 0,75mm2 -Q15
/15.8
43
53
11 21
-SA40
12 22
safety switch
-W24.2
Freig. 5 /29.2
Freig. 6 /30.2
-S50 /23.5
/31.2 -A11-X1.1
2
C 4x 0,75mm2 4 C
/14.4 K16/I 5
/14.4 K16/I 6
-X3
.
D D
14a/b
14c/d
15a/b
15c/d
16a/b
16c/d
/25.2 Freig. 1
/26.2 Freig. 2
/27.2 Freig. 3
/28.2 Freig. 4
E E
F F
Date 18.01.16 Unit -Cover switch SA40 Project number
CC36S -Servo controller release
Field -Station release
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.1
Digital output
enable K2
A A
-X16
.
1d
4d
1b
3b
2c
3c
2b
4a
A6 /49.1
.X23
-X3
.
-W-S01
28c
28b
28a
28d
ÖLFLEX CLASSIC 100 5G0,75 NCC
11 21
-S01 -W15.3
2
emergency stop button 12 -W24.1 Wire_horizontal
5
22
B Wire_vertical B
-W-S01
4
ÖLFLEX CLASSIC 100 5G0,75 NCC
bl
-W24.3
10
Wire_horizontal -W15.1
-X3
.
.
1b
4b
13 23 X1 13 23 X1 13 23 X1
-S04b -S04a -S04
11 21
-H4b -H4a -H4
C 14 24 14 24 C
-S2.1 confirm push button X2 confirm push button X2 confirm push button 14 24 X2
12 22 tie bar
emergency stop button
H4/X2 /15.3
-W24.1 -W15.1
9
Wire_horizontal ÖLFLEX 15G0,75
br
. . -W24.3
Wire_horizontal
-X3 2b 5b
D D
11 21 -X16
.
.
-S01-1
5a
6a
5b
6b
5c
6c
12 22
emergency stop button
-X3
.
-X16
3b
6b
.
-X300
.
.
-X3
4
.
E E
7c
3d
3a
6a
bridge of X16 1->2 and 3->4

/14.2 K16/I 1
/14.2 K16/I 2
/14.5 K16/I 7
/14.5 K16/I 8
F F
Date 18.01.16 Unit -Emergency stop circuit Project number
CC36S -Confirm button
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
-A1.1 -A1.1 -A1.1 -A1.1 -A1.1 -A1.5 -A1.5
digital output digital output digital output digital output digital output digital output digital output
cover open conveyor on stacking tray_tilt cover close cycle counter gripper_side_2 close strip leavings air-
cleaning
A3 /49.1 A4 /49.1 A5 /49.1 A7 /49.1 A8 /49.1 A9 /49.1 A10 /49.1
X12 X22 X13 X14 X24 X15 X25
B B
A1.1-X14/K6-11
C C
/14.8 K16/I 12
-W28.2
br LIYY 3x 0,25mm²
red
red
bk
rd
-P001 1
3 6
A1 A1 A1 A1 A1
reset
D -YA40 -Q5 -YA30 -YA20 -YA24 D
A2 A2 -R5/24 A2 A2 A2
4kW -W28.2
bk
bk
bu
gn ws LIYY 3x 0,25mm²
. . . . . .
green line
-X300 2d 6c 3a please isolate 8a 6a 6b
/15.8 X300 0V DC X300 0V DC /23.0
protection cover conveyor belt stacking tray protection cover counter gripper side 2 strip leavings
open ON tilt close close air-cleaning
E option E
1 2
/9.3
3 4
/9.3
5 6
/9.3
13 14
F F
Date 18.01.16 Unit Output Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/14.8 X301-P 24V DC X301-P 24V DC /24.0
/22.8 X300 0V DC X300 0V DC /24.0
A -X301 3b 4b 3a
A
4b 13a
-X300
/14.7
/20.5
K16/O 5
-S50
B B
-W24.1
2
-W23.1 Wire_horizontal
ÖLFLEX 2X0,5 ws
bn
bu
bn
bu
- -
13
13
-SR30 -SR31 -S50
-SA01
14
14
micro switch
bk
bk
C C
-W23.1
ÖLFLEX 2X0,5 br
-W24.1
4
Wire_horizontal
D D
X11 -A1.2 X12 -A1.2 X22 -A1.2 X13 -A1.2 -A1.2 X16
E1 /51.1 E3 /51.1 E4 /51.1 E5 /51.1 E11 /51.1
main contactor on wire feeder_close Tilting tray top stacking tray retracted cable threading
digital input digital input digital input digital input digital input
E E
F F
Date 18.01.16 Unit Input Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/23.8 X301-P 24V DC X301-P 24V DC /39.0
/23.8 X300 0V DC X300 0V DC /25.0
/15.8 X501-G 24V DC X501-G 24V DC /36.0

A A
. . -X501 .
.
-X301 -X301 2a
1c. 5a 2c.
2b
-X300 2a
10d 11b
-W15.1
11
7
ÖLFLEX CLASSIC 100 15G0,75 -W27.1
br bl Sensor connection 2.5m
/42.7 S05.13
13 13 -W27.2
B br bl Sensor connection 0.3m B
. .
-S05 -S06 . . SAP 424537
14 14
-W15.1
12
13
bn
bu
-X3
.
- - -S020 -
+
+
30a
-SA23 -SA24
C C
/14.0 Schh. schl.
/14.8
bk
A1.2/E10
-W27.2
. . sw Sensor connection 0.3m
SAP 424537
D -W27.1 D
sw Sensor connection 2.5m
X24 -A1.2 X15 -A1.2 X25 -A1.2 X26 -A1.2 X25 -A1.6
E8 /51.1 E9 /51.1 E10 /51.1 E12 /51.1 E10 /51.1
side 1 position SL3100 DT-Protectioncover open DT-Protectioncover side 2 position SL3100 gripper_side_2 up close
close
digital input digital input digital input digital input digital input
E E
F F
Cover OPEN/CLOSE SL3100 position
message
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.3 -A1.3
station connection
A side 1 station 1 P1 side 1 station 1 P3 A
-XST 1 2 3 4
wh
bn
gn
ye
A1 /49.5 A3 /49.5
X11 X12
-A1.3 -A1.3
digital output digital output free cable end
insulate
side 1 station 1 P2 side 1 station 1 P4
B B
/20.4
A2 /49.5 A4 /49.5
Freig. 1
X21 X22
grey
pink
blue
red
C C
X21 -A1.4 X22 -A1.4

E2 /51.5 E4 /51.5
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
digital input digital input
D D
X11 -A1.4 X12 -A1.4
wh-gn
bk
E1 /51.5 E3 /51.5
. .
-X300 9a -X3 17a side 1 station 1 P1 side 1 station 1 P3
/27.4 F4 F4 /26.3
24V DC
E E
/24.8 X300 0V DC X300 0V DC /26.0
side 1 station 1
F F
Date 18.01.16 Unit station connector Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.3 -A1.3
station connection
-XST 1 2 3 4
wh
bn
gn
ye
A5 /49.5 A7 /49.5
X13 X14
-A1.3 -A1.3
insulate
/20.4
B B
A6 /49.5 A8 /49.5
Freig. 2
X23 X24
grey
pink
blue
red
C C
X23 -A1.4 X24 -A1.4

E6 /51.5 E8 /51.5
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
D D
wh-gn
X13 -A1.4 X14 -A1.4
bk
E5 /51.5 E7 /51.5
. .
-X300 9b -X3 18a side 1 station 2 P1 side 1 station 2 P3
/25.4 F4 F4 /27.3
24V DC
E E
/25.1 X300 0V DC X300 0V DC /27.0
side 1 station 2
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.9 -A1.9
station connection
-XST 1 2 3 4
wh
bn
gn
ye
A1 /50.1 A3 /50.1
X11 X12
-A1.9 -A1.9
insulate
/20.5
B B
A2 /50.1 A4 /50.1
Freig. 3
X21 X22
grey
pink
blue
red
C C
X21 -A1.10 X22 -A1.10

E2 /52.2 E4 /52.2
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
D D
X11 -A1.10 X12 -A1.10
wh-gn
bk
E1 /52.2 E3 /52.2
. .
-X300 9c -X3 19a side 1 station 3 P1 side 1 station 3 P3
/26.4 F4 F4 /25.3
24V DC
E E
/26.1 X300 0V DC X300 0V DC /28.0
side 1 station 3
F F
CC36S option
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.5 -A1.5
station connection
-XST 1 2 3 4
wh
bn
gn
ye
A1 /49.1 A3 /49.1
X11 X12
-A1.5 -A1.5
insulate
/20.5
B B
A2 /49.1 A4 /49.1
Freig. 4
X21 X22
grey
pink
blue
red
C C
X21 -A1.6 X22 -A1.6

E2 /51.1 E4 /51.1
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
D D
X11 -A1.6 X12 -A1.6
wh-gn
bk
E1 /51.1 E3 /51.1
. .
-X300 10a -X3 20a side 2 station 1 P1 side 2 station 1 P3
/30.4 F5 F5 /29.3
24V DC
E E
/27.1 X300 0V DC X300 0V DC /29.0
side 2 station 1
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.5 -A1.5
station connection
-XST 1 2 3 4
wh
bn
gn
ye
A5 /49.1 A7 /49.1
X13 X14
-A1.5 -A1.5
insulate
/20.4
B B
A6 /49.1 A8 /49.1
Freig. 5
X23 X24
grey
pink
blue
red
C C
X23 -A1.6 X24 -A1.6

E6 /51.1 E8 /51.1
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
D D
X13 -A1.6 X14 -A1.6
wh-gn
bk
E5 /51.1 E7 /51.1
. .
-X300 10b -X3 21a side 2 station 2 P1 side 2 station 2 P3
/28.4 F5 F5 /30.3
24V DC
E E
/28.1 X300 0V DC X300 0V DC /30.0
side 2 station 2
F F
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A1.9 -A1.9
station connection
-XST 1 2 3 4
wh
bn
gn
ye
A5 /50.1 A7 /50.1
X13 X14
-A1.9 -A1.9
insulate
/20.5
B B
A6 /50.1 A8 /50.1
Freig. 6
X23 X24
grey
pink
blue
red
C C
X23 -A1.10 X24 -A1.10

E6 /52.2 E8 /52.2
rd-bu
gy-pk
wh-ye
wh-gn
bn-gn
-XST
bk
bu
gy
pk
rd
vt
9 10 11 15 7 5 6 8 12 14
13
D D
X13 -A1.10 X14 -A1.10
wh-gn
bk
E5 /52.2 E7 /52.2
. .
-X300 9d -X3 22a side 2 station 3 P1 side 2 station 3 P3
/29.4 F5 F5 /28.3
24V DC
E E
/29.1 X300 0V DC X300 0V DC /31.6
side 2 station 3
F F
CC36S option
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
remove bridge
-A12-X1.1 /32.2
Kl. 10-11 /30.1 X300 0V DC X300 0V DC /36.0
A A
.
-X300
/32.2
(X-11) 7d
-X51 (Option)
/10.2
/10.2
/10.2
/10.2
/32.6
/32.6
/47.3
/32.7
D-Sub 15pol 10
-A12-X1.8 /32.5
-A12-X1.10 /32.5
-A11-X1.2
prefeeder
ready
-K1
-A12-X1.14
-A12-X1.17
/20.6
/15.5
/15.6
/12.0
A11-L1
A11-L2
A11-L3
A11-PE
-A11
-A12
or
bypass connector
-X51
-A11-X1.1
B B
-A11-X1.14
Enable 24V STO
Enable 0V STO
. (X-11) 11
1,5 mm²
A11-X1.17/X300-7d
10b
-X3
. -A11-X1.2/X3-11b
-X3 11b
C C
X3 1 2 3 4 X1 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18
0 x16
-A11 L1 L2 L3 AC 114 adress
End+
End-
Ref.
Trigger 1
quickstop
COM (1,2)
+24V ETHERNET
1
Shield
COM (9)
X1
(5-7,14,15)
COM
Powerl.Interface
enable
Slot 1
2 X2 X2 3
+DC1 +DC2
1 4
-DC1
motor
Slot 2 Slot 3 -DC2
resolver incremental
B+ B- T+ T- U V W AC122 encoder
AC123
B&R ACOPOS 8V1016
D X4 4 3 2 1 X5 4 3 2 1 D
Assigment of the plug of the incremental encoder slot 3
1 = green Channel A
wh/bu
wh/gn
wh/rd
gn/ye
2 = yellow Channel A
/16.8 B11/K17_R1
3 = grey Channel B
wh
bu
bn
bk
-W-M11 4 = pink Channel B

8CM004.12-1 -W-B11-1 -W-B11-2 5 = bridge to 9 Ref.
6 = bridge to 12 Ref.
7 = -
U V W PE 8 = -
9 = brown + 5V
E M 10 = - E
3 11 = -
T T 12 = white 0 V
13 = -
-B11-1 -B11-2 14 = bridge to 15
15 = bridge to 14 Observe mounting and
-M11 slip monitoring
wire feeder installation instruction
+ haul-off 1
of manufacturer
F F
Date 18.01.16 Unit drive wire feeder Project number
CC36S drive haul-off 1
Field A11 and M11
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A13-X1.1 /33.2
A A
/31.2
/33.2
/10.3
/10.3
/10.3
/10.3
/33.5
/33.6
/33.6
/31.7
/33.7
-A11-X1.2 /31.2
-A13-X1.10 /33.5
-A12-X1.1
-A12-X1.2
A12-L1
A12-L2
A12-L3
A12-PE
-A12
-A13
-A13-X1.8
-A13-X1.14
-A13-X1.17
/31.5
/31.5
/31.6
/31.6
B B
-A12-X1.10
1,5 mm²
-A12-X1.8
-A12-X1.14
-A12-X1.17
C C
X3 1 2 3 4 X1 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18
0 x16
End+
End-
Ref.
Trigger 1
quickstop
COM (1,2)
+24V ETHERNET
2
Shield
COM (9)
X1
(5-7,14,15)
COM
Powerl.Interface
enable
Slot 1
2 X2 X2 3
+DC1 +DC2
1 4
-DC1
motor
Slot 2 Slot 3 -DC2
resolver AC130 B&R ACOPOS 8V1016
B+ B- T+ T- U V W AC122 Printerconnector
D X4 4 3 2 1 X5 4 3 2 1 (Option) D
resolver slot 2
AC122
wiring diagramm 50000436566

pin terminal SUB D
wh/bu
wh/gn
wh/rd
gn/ye
pin pin
/16.8 B12/K17_R2
wh
bu
bn
bk
-W-M12 9 Ref. 9 = pk
8CM003.12-1 -W-B12-1 5 Ref. 5 = gy
7 Cos 7 = ye
Printerconnector
3 Cos 3 = gn
U V W PE 4 Sin 4 = wh
8 Sin 8 = bn
E M E
3 shield stuck on
T case attached
-B12-1
Observe mounting and
-M12
cutting head installation instruction
of manufacturer
F F
Date 18.01.16 Unit drive cutting head Project number
CC36S A12 and M12
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A15-X1.1 /34.2
A A
/32.2
/34.2
/10.4
/10.4
/10.4
/10.4
/34.5
/34.6
/34.6
/32.7
/34.7
-A12-X1.2 /32.3
-A15-X1.10 /34.5
-A13-X1.1
-A13-X1.2
A13-L1
A13-L2
A13-L3
A13-PE
-A13
-A15
-A15-X1.8
-A15-X1.14
-A15-X1.17
/32.5
/32.5
/32.6
/32.6
B B
-A13-X1.10
1,5 mm²
-A13-X1.8
-A13-X1.14
-A13-X1.17
C C
X3 1 2 3 4 X1 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18
0 x16
End+
End-
Ref.
Trigger 1
quickstop
COM (1,2)
+24V ETHERNET
3
Shield
COM (9)
X1
(5-7,14,15)
COM
Powerl.Interface
enable
Slot 1
2 X2 X2 3
+DC1 +DC2
1 4
-DC1
motor
Slot 2 Slot 3 -DC2
resolver B&R ACOPOS 8V1016
B+ B- T+ T- U V W AC122
D X4 4 3 2 1 X5 4 3 2 1 D
resolver slot 2
AC122
pin terminal SUB D
wh/bu
wh/gn
wh/rd
gn/ye
pin pin
/17.8 B13/K18_R1
wh
bu
bn
bk
-W-M13 9 Ref. 9 = pk
8CM005.12-1 -W-B13-1 5 Ref. 5 = gy
7 Cos 7 = ye
3 Cos 3 = gn
8 Sin 8 = bn
E M E
3 shield stuck on
T case attached
-B13-1
-M13
swivel arm 1 installation instruction
side 1
of manufacturer
F F
Date 18.01.16 Unit drive swivel arm 1 Project number
CC36S A13 and M13
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
-A16-X1.1 /35.2
A A
/33.2
/35.2
/10.5
/10.5
/10.5
/10.5
/35.5
/35.6
/35.6
/33.7
/35.7
-A13-X1.2 /33.3
-A16-X1.10 /35.5
-A15-X1.1
-A15-X1.2
A15-L1
A15-L2
A15-L3
A15-PE
-A15
-A16
-A16-X1.8
-A16-X1.14
-A16-X1.17
/33.5
/33.5
/33.6
/33.6
B B
-A15-X1.10
1,5 mm²
-A15-X1.8
-A15-X1.14
-A15-X1.17
C C
X3 1 2 3 4 X1 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18
0 x16
End+
End-
Ref.
Trigger 1
quickstop
COM (1,2)
+24V ETHERNET
5
Shield
COM (9)
X1
(5-7,14,15)
COM
Powerl.Interface
enable
Slot 1
2 X2 X2 3
+DC1 +DC2
1 4
-DC1
motor
Slot 2 Slot 3 -DC2
B+ B- T+ T- U V W AC122
D X4 4 3 2 1 X5 4 3 2 1 D
resolver slot 2
AC122
pin terminal SUB D
wh/bu
wh/gn
wh/rd
gn/ye
pin pin
/18.8 B15/K19_R1
wh
bu
bn
bk
-W-M15 9 Ref. 9 = pk
8CM003.12-1 -W-B15-1 5 Ref. 5 = gy
7 Cos 7 = ye
3 Cos 3 = gn
8 Sin 8 = bn
E M E
3 shield stuck on
T case attached
-B15-1
-M15
swivel arm 2 installation instruction
side 2
of manufacturer
F F
Date 18.01.16 Unit drive swivel arm 2 Project number
CC36S A15 and M15
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
/34.2
/10.5
/10.6
/10.6
/10.6
/14.7
/34.6
/34.6
/34.7
-A15-X1.2 /34.3
-A16-X1.1
-A16-X1.2
A16-L1
A16-L2
A16-L3
A16-PE
-A16
-A16-X1.14
-A16-X1.17
/34.5
/34.5
B B
-A16-X1.10
-A16-X1.8
1,5 mm²
C C
X3 1 2 3 4 X1 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18
0 x16
End+
End-
Ref.
Trigger 1
quickstop
COM (1,2)
+24V ETHERNET
6
Shield
COM (9)
X1
(5-7,14,15)
COM
Powerl.Interface
enable
Slot 1
2 X2 X2 3
+DC1 +DC2
1 4
-DC1
motor
Slot 2 Slot 3 -DC2
B+ B- T+ T- U V W AC122
D X4 4 3 2 1 X5 4 3 2 1 D
resolver slot 2
AC122
pin terminal SUB D
wh/bu
wh/gn
wh/rd
gn/ye
pin pin
/18.8 B16/K19_R2
wh
bu
bn
bk
-W-M16 9 Ref. 9 = pk
8CM003.12-1 -W-B16-1 5 Ref. 5 = gy
7 Cos 7 = ye
3 Cos 3 = gn
8 Sin 8 = bn
E M E
3 shield stuck on
T case attached
-B16-1
-M16
pull-off unit installation instruction
side 2
of manufacturer
F F
Date 18.01.16 Unit drive pull-off unit 2 Project number
CC36S A16 and M16
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/24.8 X501-G 24V DC X501-G 24V DC /37.0
/31.8 X300 0V DC X300 0V DC /37.0
A -X501 1c
A
-X300 8c -A1.3
digital output
paper winder side_1
-W-X40
UNITRONIC 5x0,34 sw gegr bl br A11 /49.5
bk
bu
bn
X16
B bk B
bu
bn
. . . .
-X40 -X40 -X40 -X40
4 PE 3 1
C C
bn
1 2 3
13 -A40
-S040 + X1 - X5
cam switch X3
enable ON CHV2500
compensator 14
RS 485
1 2
bk
stepper motor Hall-effect connector RJ 45
D X4 J2 D
1A 1B 2A 2B 1 2 3 4 5 6 7 8
-X40 . 2
-W-X40 rd ye bu og
UNITRONIC 5x0,34 ws
wh
X16 -A1.4
E11 /51.5
paper winder side_1

M
E -M40 E
digital input
paper winder 1 side 1

(station 1 or 2)
F F
Date 18.01.16 Unit paperwinder side 1 Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/36.8 X501-G 24V DC X501-G 24V DC /38.0
/36.8 X300 0V DC X300 0V DC /38.0
A -X501 2c
A
-X300 8d -A1.1
digital output
paper winder side_1

station 3
-W-X50
UNITRONIC 5x0,34 sw gegr bl br
A11 /49.1
bk
bu
bn
X16
B bk B
bu
bn
. . . .
-X50 -X50 -X50 -X50
4 PE 3 1
C C
bn
1 2 3
13 -A50
-S050 + X1 - X5
cam switch X3
enable ON CHV2500
compensator 14
RS 485
1 2
bk
D X4 J2 D
1A 1B 2A 2B 1 2 3 4 5 6 7 8
-X50 . 2
-W-X50 rd ye bu og
UNITRONIC 5x0,34 ws
wh
X16
E11 /52.2
paper winder side_1 M

E station_3 -M50 E
digital input
-A1.10
paper winder 2 side 1

(station 3)
F F
Date 18.01.16 Unit paper winder 2 side 1 Project number
Field
(Option)
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/37.8 X501-G 24V DC
/37.8 X300 0V DC X300 0V DC /39.0
A -X501 1d
A
-X300 8b -A1.5
digital output
paper winder side_2
-W-X41
UNITRONIC 5x0,34 sw gegr bl br A11 /49.1
bk
bu
bn
X16
B bk B
bu
bn
. . . .
-X41 -X41 -X41 -X41
4 PE 3 1
C C
bn
1 2 3
13 -A41
-S041 + X1 - X5
cam switch X3
enable ON CHV2500
compensator 14
RS 485
1 2
bk
D X4 J2 D
1A 1B 2A 2B 1 2 3 4 5 6 7 8
-X41 . 2
-W-X41 rd ye bu og
UNITRONIC 5x0,34 ws
wh
X16 -A1.6
E11 /51.1
paper winder side_2

M
E -M41 E
digital input
paperwinder side 2
F F
Date 18.01.16 Unit paperwinder side 2 Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/24.8 X301-P 24V DC X301-P 24V DC /40.0
/38.8 X300 0V DC X300 0V DC /40.0
A A
-X301 1b 2b
1b 2b
-X300
B B
bn
bu
bn
bu
- -
+
+
C -S011 -S021 C
bk
bk
(Option) (Option)
D D
X15 -A1.4 X15 -A1.6

E9 /51.5 E9 /51.1
gripper_side_1_up gripper_side_2 up
E E
gripper up gripper up
side 1 side 2
(Option) (Option)
F F
Date 18.01.16 Unit Gripper side 1 and 2 optional Project number
CC36S sensors
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/39.8 X301-P 24V DC X301-P 24V DC /41.0
/39.8 X300 0V DC X300 0V DC /42.0

.
A -X301 5b A
. option option
-X300 13b
CC ground point ground point
0V 0V
Switch symbol
Chassis Chassis
St.3 st.1
B P3 0 P1 B
-U51 A1 13+ A1 13+
last contact
last contact
13 23
L M R
-U52
-S60
14 24
End of Crimp
End of Crimp
. A2 14 A2 14
C C
station 1 station 3
D D
-S60 switch setting
"0" middle = station 1 and 3 is monitored X26 -A1.4

"P1" right = station 1 is monitored
"P3" left = station 3 is monitored E12 /51.5
last contact_side_1
digital input
E E
(Option)
F F
Date 18.01.16 Unit goods control Project number
CC36S (option)
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/40.8 X301-P 24V DC X301-P 24V DC /43.0
.
A -X301 4d A
option
ground point
0V
Chassis
B B
A1 13+
last contact
-U61
End of Crimp
. A2 14
C C
D D
X26 -A1.6
E12 /51.1
last contact_side_2
digital input
E E
(Option)
F F
Date 18.01.16 Unit goods control Project number
CC36S (option)
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
-A1.7 -A1.7 -A1.7
digital output digital output digital output S05.13 /24.2
Towerlight_red Towerlight_yellow Towerlight_green
A4 /49.5 A5 /49.5 A6 /49.5

13
X22 X13 X23
-S013
B 14 B
configuration
.
P1
24d bell
-W15.1
ÖLFLEX 15G0,75 14
H10
red
. . .
C C
-X3 24a 24b 25b H11
yellow
-W-TLB1
Ölflex 7G0,75 5 4 3 2 1 H12
green
H13
blue
bell failure setting running service
(Option) 4 3 2 1
D 5 D
-H10 -H11 -H12 -H13
-P1 red yellow green blue
0
-W-TLB1
ÖLFLEX 7G0,75 6
.
-X300 1c
E E
/40.8 X300 0V DC X300 0V DC /43.0
F F
Date 18.01.16 Unit Towerlight Project number
CC36S (Option)
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/41.8 X301-P 24V DC X301-P 24V DC /44.0
-A1.7
.
A digital output -X301 A
5d
special A14
A3 /49.5
X12
B B
A1 13+ A1 13+
-S1
-R1 1 -U70 -U71

22K 0,6W
C C
2
-W33.1
ÖLFLEX 2X0,5 2 1 A2 14 A2 14
X13 -A1.8
E5 /51.6
D Splice detection D
free cable end

insulate
. . digital input
-X300
5d 4a
/42.8 X300 0V DC X300 0V DC /44.0
E E
F F
Date 18.01.16 Unit Splice-Check Project number
CC36S (optional)
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
/43.8 X301-P 24V DC
/43.8 X300 0V DC X300 0V DC /47.0
A A
-X301 5c
brown .
-X300 10c
white
B B
2,1m
40 mm
0,2m
plastic-sheathed cable 2 wire

2 x 0.25mm² max. 0.35mm²
brown
.
+
12,5 mm
24 VDC
C -D2 -D2 -D2 -D2 -D2 -D2 end sleeve C
white
.
-
2 pin connector cable cross-section

0.25mm² up to 0.35mm²
107,5 mm
D D
E E
SAP Nr.: 433805
F F
Date 18.01.16 Unit LED light cutter head Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
(Option)
(printer connection)
AC130
wire feeder
CPU haul-off unit 1 cutting head swivel arm unit 1 swivel arm unit 2 haul-off unit 2
B -A 1 -A11 -A12 -A13 -A15 -A16 B
AC 112 AC 112 AC 112 AC 112 AC 112

ETHERNET ETHERNET ETHERNET ETHERNET ETHERNET ETHERNET
powerlink powerlink powerlink powerlink powerlink powerlink
Interface Interface Interface Interface Interface Interface
Adr. Adr. Adr. Adr. Adr. Adr.

x16 X1 x16 X1 x16 X1 x16 X1 x16 X1 x16 X1
D 3 0 1 0 2 0 3 0 5 0 6
IF3
C . . . . . . . . . . . C
2,0m 0,3m 0,3m 0,3m 0,3m
D D
E E
Attend to: calibration of address
F F
Date 18.01.16 Unit ACOPS powerlink Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
/5.6
Switch
B B
-A1 /47.3
P-PC
s1.st1
-G3
s1.st2
- + s1.st3 (Option)
s2.st1
C s2.st2 C
s2.st3 (Option)
. . . . . . . .
.
D D
Switch 10/100 Fast Ethernet
E E
F F
Date 18.01.16 Unit Switch Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A
-A 1 -A2 -A 1 A
X20 CP1484 LED LED
8 0 0
x16
. TX. RX
Flash
4
11 21
CF-Card 512MB
C
. . Gnd
B 8 0 0
X1
12 22 B
4 . .
13 23
0
. .
CAN GND 1 gn
Up from EASY 4.2 is the CAN L 2 wh 14 24
address setting
modified
C D 4
x16 Shield
CAN H
3
4 bn . +24V
.
NC 5
8 run
15 25
C 0 C
BOOT
. . GND
3 X1 DIAG
C 4
16 26
battery (Option)
8
X20 IF 1072 IF1-RS232
IF2 IF3 IF4 IF5

ETH EPL USB USB
/12.1 CPU
switch for
/31.7 -A11 resistor
/46.6 -A1
"ON" selected to front

D (dir. CAN-connector) D
selection visible
via LED "TERM"
.
-X300 1a
/44.8 X300 0V DC
E E
Attend to: calibration of address
F F
Date 18.01.16 Unit SPS CPU1484 Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A standard flaring A
-A1.1 -A1.2 -A1.3 -A1.4 -A1.5 -A1.6 -A1.7 -A1.8 -A1.9 -A1.10 -A1.11 -A1.12 -A1.13 -A1.14 -A1.15 -A1.16
out IN out IN out IN out IN out IN out IN out IN out IN

B B
LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21 11 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22 12 22
C C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23 13 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24 14 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25 15 25
D D
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26 16 26
X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371 X20DO9322 X20DI9371
all modules are 12-pin terminal
E E
F F
Date 18.01.16 Unit block diagram SPS I/O Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A -A1.1 -A1.3 A
digital output Do9322 digital output Do9322
Output 12 Output 24VDC Output 12 Output 24VDC
X11 A1 /19.0 main contactor enabled X11 A1 /25.0 side 1 station 1 P1

X21 A2 /19.2 controller release_ON X21 A2 /25.1 side 1 station 1 P2
X12 A3 /22.0 cover open X12 A3 /25.1 side 1 station 1 P3
X22 A4 /22.1 conveyor on X22 A4 /25.2 side 1 station 1 P4
B X13 A5 /22.2 stacking tray_tilt X13 A5 /26.0 side 1 station 2 P1 B
X23 A6 /21.8 enable K2 X23 A6 /26.1 side 1 station 2 P2
X14 A7 /22.3 cover close X14 A7 /26.1 side 1 station 2 P3
X24 A8 /22.4 cycle counter X24 A8 /26.2 side 1 station 2 P4
X15 A9 X15 A9 gripper_side_1_close
X25 A10 X25 A10 STW_1100_exhaust
X16 A11 /37.5 paper winder side_1 station 3 X16 A11 /36.5 paper winder side_1
X26 A12 X26 A12 STW_1100 clamping
C C
-A1.5 -A1.7
digital output Do9322 digital output Do9322
Output 12 Output 24VDC Output 12 Output 24VDC

D D
X11 A1 /28.0 side 2 station 1 P1 X11 A1 conveyor speed bit 0

X21 A2 /28.1 side 2 station 1 P2 X21 A2 conveyor speed bit 1
X12 A3 /28.1 side 2 station 1 P3 X12 A3 /43.2 special A14
X22 A4 /28.2 side 2 station 1 P4 X22 A4 /42.1 Towerlight_red
X13 A5 /29.0 side 2 station 2 P1 X13 A5 /42.2 Towerlight_yellow
X23 A6 /29.1 side 2 station 2 P2 X23 A6 /42.4 Towerlight_green
X14 A7 /29.1 side 2 station 2 P3 X14 A7 special A7
X24 A8 /29.2 side 2 station 2 P4 X24 A8 special A8
X15 A9 /22.5 gripper_side_2 close X15 A9 special A9
X25 A10 /22.7 strip leavings air-cleaning X25 A10 special A10
X16 A11 /38.5 paper winder side_2 X16 A11 special A11
E X26 A12 X26 A12 special A12 E
F F
Date 18.01.16 Unit PLC Outputmodul Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A -A1.9 A
digital output Do9322
Output 12 Output 24VDC
X11 A1 /27.0 side 1 station 3 P1

B X13 A5 /30.0 side 2 station 3 P1 B
X15 A9 printer text selection bit 0
C C
D D
E E
F F
Date 18.01.16 Unit PLC Outputmodul Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A -A1.2 -A1.4 A
digital input DI 9371 digital input DI 9371
Input 12 Input 24VDC Input 12 Input 24VDC
X11 E1 /23.0 main contactor on X11 E1 /25.4 side 1 station 1 P1

X21 E2 /19.7 Emergency stop relay on X21 E2 /25.5 side 1 station 1 P2
X12 E3 /23.1 wire feeder_close X12 E3 /25.6 side 1 station 1 P3
X22 E4 /23.2 Tilting tray top X22 E4 /25.7 side 1 station 1 P4
B X13 E5 /23.4 stacking tray retracted X13 E5 /26.4 side 1 station 2 P1 B
X23 E6 /19.4 protection cover_close X23 E6 /26.5 side 1 station 2 P2
X14 E7 /19.6 Emergency stop relay on X14 E7 /26.6 side 1 station 2 P3
X24 E8 /24.1 side 1 position SL3100 X24 E8 /26.7 side 1 station 2 P4
X15 E9 /24.2 DT-Protectioncover open X15 E9 /39.0 gripper_side_1_up
X25 E10 /24.3 DT-Protectioncover close X25 E10 protection cover_close
X16 E11 /23.5 cable threading X16 E11 /36.1 paper winder side_1
X26 E12 /24.4 side 2 position SL3100 X26 E12 /40.7 last contact_side_1
C C
-A1.6 -A1.8
digital input DI 9371 digital input DI 9371
Input 12 Input 24VDC Input 12 Input 24VDC

D D
X11 E1 /28.4 side 2 station 1 P1 X11 E1 feed-back signal Printer start

X21 E2 /28.5 side 2 station 1 P2 X21 E2 printer_1_ready
X12 E3 /28.6 side 2 station 1 P3 X12 E3 wire feeder open/close
X22 E4 /28.7 side 2 station 1 P4 X22 E4 special E14
X13 E5 /29.4 side 2 station 2 P1 X13 E5 /43.3 Splice detection
X23 E6 /29.5 side 2 station 2 P2 X23 E6 sensitive strip
X14 E7 /29.6 side 2 station 2 P3 X14 E7 Hot-Stamp 2 ready
X24 E8 /29.7 side 2 station 2 P4 X24 E8
X15 E9 /39.2 gripper_side_2 up X15 E9 special E10
X25 E10 /24.6 gripper_side_2 up close X25 E10 special E11
X16 E11 /38.1 paper winder side_2 X16 E11 special E12
E X26 E12 /41.4 last contact_side_2 X26 E12 E
F F
Date 18.01.16 Unit PLC Inputmodul Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A -A1.10 A
digital input DI 9371
Input 12 Input 24VDC
X11 E1 /27.4 side 1 station 3 P1

B X13 E5 /30.4 side 2 station 3 P1 B
X15 E9 special E13
X25 E10
X16 E11 /37.1 paper winder side_1 station_3
X26 E12
C C
D D
E E
F F
Date 18.01.16 Unit PLC Inputmodul Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
see page 27.2
cabinet
B B
gripper swivel arm side 2
50000133419
Sensor interchange parts

terminal block
and PLC
length 0,2m length 0,3m ca. length 2,2m
.
424537 50920008397
C C
50920010576
Fastening clip
429809
D D
E E
F F
Date 18.01.16 Unit Description interchange parts Project number
CC36S swivel arm side 2
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
F F
Date 18.01.16 Unit terminal block 1 24V Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
F F
Date 18.01.16 Unit terminal block 1 24V Project number
Field
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6 7 8
A A
B B
C C
D D
E E
F F
Date 18.01.16 Unit terminal block 2 power line Project number
Field
0 1 2 3 4 5 6 7 8

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CrimpCenter 36 S

Schleuniger GmbH Schleuniger, Inc.

Schleuniger AG Schleuniger Japan Co., Ltd.

Schleuniger AG Schleuniger Trading (Shanghai) Co., Ltd.

© 2015 Schleuniger | ID-0000000098-006-EN

2 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

2.11.2 Protective clothes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 TRANSPORT / PACKAGING / STORAGE 28

4 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

5.5 PROCESSING STATIONS AND OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6 SAFETY ELEMENTS / DANGER AREAS 67

9 SERVICING / MAINTENANCE 107

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

9.2.2 Personnel qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

10 SPARE PARTS 200

11 DECOMMISSIONING / DISPOSAL 201

12 OVERVIEW OF SYMBOLS 203

13 WIRING DIAGRAMS 210

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

1.1 MANUFACTURERS ADDRESS

1.2 MANUFACTURING DATE / PRODUCT TYPE

1.3 INFORMATION ABOUT THE OPERATING INSTRUCTIONS

1.3.1 Contents of the manual

8 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

Operating Manual - CrimpCenter

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

1.4 GENERAL SYMBOLS AND LEGEND

1.4.1 References and Hints

Symbol Meaning Description

Dispose-off Environmental contaminating substances to return to supplier.

Mark-up Meaning Description

The following abbreviations are used.

Abbreviation Meaning Description

10 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

Abbreviation Meaning Description

1.5 DECLARATION OF CONFORMITY

1.6 LIMITATION OF LIABILITY

1.7 WARRANTY STATEMENTS AND POLICIES

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

1.8 COPYRIGHT PROTECTION

12 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

1.9 SPARE PARTS

1.11 MISUSE AND MODIFICATIONS

1.12 ENVIRONMENTAL PROTECTION

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

1.13 SERVICE HOTLINE

14 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

2.1 WARNING NOTICES

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

2.2 SAFETY REGULATIONS

16 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

Failure to do so may result in serious injury or death.

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

2.3 SOURCES OF DANGER / RESIDUAL RISKS

18 | 212 Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S

2.4 INTENDED USAGE OF PRODUCT

Original Manual | Edition 1.4 (08-2015) | CrimpCenter 36 S