Rittal 4051.021 Operating Instructions Manual Download Page 1 | Manualshive

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4051.021

Crimping machine R8-I

Operating instructions

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Summary of Contents for 4051.021

Page 1: ...4051 021 Crimping machine R8 I Operating instructions ...

Page 2: ... 1 Normal operation 15 6 2 Inserting aconductor 15 6 3 Touch display and operating menus 15 6 4 Resetting the daily counter 16 6 5 Switching the operating mode 17 6 6 Displayingcounters and the machining time 17 6 7 Settingthe language 17 6 8 Service display 18 6 9 Switchingoff the automatic machine 18 7 Cleaning and maintaining the automatic machine 18 7 1 Cleaningthe automatic machine exterior 1...

Page 3: ...Contents Rittal crimping machine R8 I We reserve the right to make technical modifications 3 EN 9 2 Disposingof the automatic machine 28 10 Pneumatic diagram 29 11 Electric diagram 30 12 Conformity 32 ...

Page 4: ...specified no tices Attention Propertydamage Noticeswith the signal word Attention warn youaboutdangersthatcould re sultin property damage Situation related warningsmay contain the followingwarningsymbols Symbol Meaning Warning Dangerous voltage Warning Injury to hands due to sharp blades Warning Injury to hands crushing Work may be performed only by a qualified electrician Perform work only with p...

Page 5: ...documentation Rittal crimping machine R8 I We reserve the right to make technical modifications 5 EN Enumerationsareindicatedwith dashes Operatinginstructionsin other languagescan be foundon our website Click here ...

Page 6: ...ntendeduse also includesthe observanceof the complete documentation All other usesare deemedasimproper An improperuse is one thatis notknown to the manufacturer Secureoperationisnotensuredand the manufacturer sliability isexcludedfor the non observanceof thesespecifications 2 2 Processablematerialandcrimping form Conductors Flexible H05V Kand H07V KPVC conductorswith across sectionof 0 5 2 5 mm No...

Page 7: ...y Repairsmay be performedonly afterconsultationwith Rittal Service and only by aqualified electrician Keep theseoperatinginstructionsatasafe place for future reference by operatingpersonnel whenneeded 3 Unit description Fig 1 Front view Legend 1 Sleeve feeding funnel 2 Front panel latch 3 Touch display 4 Conductor feeding funnel with insert 5 Front panel 6 Waste chute 7 Carrying handle on both sid...

Page 8: ...m 5 Fall out plate 6 Stranded wire fixing unit 7 Insulation stripping unit 8 Opening chock 3 1 Technical specifications Crimping machine R8 I Drive electro pneumatic Power supply 1 100 240 V AC 50 60 Hz Power consumption 16 VA Fuse mains filter module 2 x T2AH250V Maximum short circuit current SCCR 1 5 kA Protection category IP 20 Protection class I PE conductor Operating pressure 5 5 bar 3 8 7 1 ...

Page 9: ...ternal temperature during operation max 45 C Max operating altitude 2000 m above mean sea level Humidity 50 at 40 C without condensation 90 at 20 C without condensation Contamination level 2 Continuous sound pressure level 70 dB A Dimensions W x D x H 390 x 330 x 460 mm 15 35 x 12 99 x 18 11 Colour RAL 9003 RAL 7016 Weight 23 kg 50 71 lbs 3 2 Rating plate Symbol Meaning Operate automatic machines ...

Page 10: ...rimpingresultscannotbe achievedwith lessthan 5 bar operat ingpressure Increasedwear on theautomatic machinecan occur with morethan 6 bar operatingpressure 4 2 Transporting anautomaticmachine Caution Alwayswear work shoeswith footprotection when transporting the automatic machine Before transportation alwaysemptythe waste container Consider the weightof the automatic machine see section3 1 If neces...

Page 11: ...ompressed air source Check the manometerdisplay fig 3 item2 The operatingpressuremustbe between 5 and 5 5bar If necessary adjustthe operatingpressureby pullingthe adjustingscrewup wards fig 3 item1 and turningitcarefully Turn clockwiseto increasethe pressure Turn counter clockwise to decreasethe pressure Insertthe mainscable in the mainsconnection socket fig 3 item4 of the auto matic machine and c...

Page 12: ...ntil only the conductor isstrippedof insulation All wire end ferruleshave nowbeen removedfrominsidethe crimpingunit The followingsettingsmustbe checked and modifiedwhenrequired for every configuration Wire end ferrulereel Sleeve cross section Note The automatic machine mustbe switchedoff whenconfiguring 5 1 Inserting wireend ferrules Place the wire end ferrulereel fig 4 item1 so thatclockwiseunrol...

Page 13: ... locatedbelowthe transportlever Check for correctseatingby pullingcarefully atthe wire endferrulebelt Close and latch the frontpanel Roll up the loose wire endferrulebelt 5 2 Inserting thefeeding funnel The feedingfunnel mustbe changedfor the followingsituations When aconductorwith adifferentcross section isto be processed Conductorcross sectionsareassigned to eachletter A 0 5 0 75 mm B 1 1 5 mm C...

Page 14: ... Hasthe insulation been stripped straightand uniformly Check with one of the uncrimped wireendferruleswhetherthe strippinglength is correctand whether theselected combination of conductor and sleeve matchesoptimally 5 5 Setting the cut depth Dependingon the hardnessand thicknessof the insulation itmay be necessary to modify the cutdepth for theinsulationstripping Thisrequiresthatthe cutterseparati...

Page 15: ...tactyour Rittal Service Switch on the mainsswitch The valvesactuate audibly and homingisperformed The touchdisplay showsop erational readiness 6 2 Inserting a conductor Note Processonlyconductorscutcleanly All strandedwiresmusttermi nate flush with the insulation no stranded wiremay be shortened or protrude Ensure thatthe conductorendisinserted straight Fig 7 Insert conductor correctly Insertacond...

Page 16: ...Within amenu pressthe arrowkeys to move to the desired item To activate aselected item press E To exitthe menu press C Only menus1 3 and 10 are relevantfor operation Menus Menu 1 Resetdaily counter Menu 3 Switch operatingmode standard crimpingand insulationstripping Menu 10 Setlanguage The other menusareprovidedonly forthe Service 6 4 Resetting thedaily counter SelectMenu1 unlessitisalready displa...

Page 17: ...otal counter Number ofcompleted work cycles Mach time 1 946 s Machining time Duration of a work cycle insulation stripping and crimping Service 1 Sign and service counter C E The total counter countsthe workcyclesduringthe completeservicelifeof the automatic machine The serviceinterval of the automaticmachineis400 000work cycles The servicecountercountsdownstartingat400 000 The servicecounteris 0 ...

Page 18: ...erviceafter800 000work cycles Contactyour responsibleRittal country representative 6 9 Switching off theautomaticmachine Switch off the automatic machine The valve release canbe heardand the displayiscleared 7 Cleaning and maintaining the automatic machine 7 1 Cleaning the automaticmachine exterior The automatic machine should befreedregularly fromdust If necessary itsexte rior mustbe cleaned Note...

Page 19: ...eeasy accessto all interiorareasof the automaticma chine you shouldremovethe waste containerbeforebeginning maintenancework Do notforgetto replacethe waste container after completingthe work Note Keep the followingathand for maintenancework Allen key set Brush and cleaningcloth Lubricant PTFEoil Lubricatinggrease suitable forrollerbearings 7 3 Maintenanceschedule Maintenance point Interval mainten...

Page 20: ...ng tongs 7 7 Quarterly 7 Tool slide 7 9 When required 8 Compressed air maintenance unit Drain the condensate and clean replace the fil ter 7 10 Fig 9 Overview ofthemaintenancepoints 7 4 Maintaining the conductor holding tongs Clean the conductorholdingtongswith abrush Additional monthly maintenance Oil the conductor holdingtongsatthe pivotpoints fig 10 item1 and atthe contactsurfaces fig 10 item2 ...

Page 21: ...funnel fig 11 item1 with abrush If required useasoftcloth and methylated spirits Additional monthly maintenance Pull the stranded wirefixingunitforwards fig 11 itemB Check whetherthe rollers fig 11 item2 aresmooth running If required oil the pivotpointsof the rollers Oil the pivotpoints fig 11 item3 of the strandedwirefixingunit 7 6 Maintaining the insulation stripping unit Ensure thatthe stranded...

Page 22: ...f required replace theblades see section 8 3 Replacingthe insulation strippingblade 7 7 Maintaining the crimping tool To reach the crimpingtool you mustdismantlethe strandedwirefixingunit Ensure thatthe strandedwire fixingunitisatthe frontposition fig 11 itemB Remove the rightlower screwof the strandedwire fixingunit fig 11 item4 Remove the strandedwire fixingunitforwardscarefully Tilt the strande...

Page 23: ...Oil the guide pin fig 14 item3 of the sleeveholdingunit Oil the side runningsurfaces fig 14 item4 of the sleeveholdingunit Reinsertthe stranded wirefixingunitand tighten it 7 8 Cleaning the interior Remove the waste container Clean the interiorof the automaticmachinewith abrush and when required with a vacuumcleaner Note Never use compressedair for cleaningthe interior because small parts e g stri...

Page 24: ...nitto itsoriginal position 7 10 Maintaining the compressedair maintenanceunit Caution Risk of injury by electricshock Ensure thatthe automatic machineisswitched off and the mainsconnector is disconnected Caution Risk of injury fromaslewingcompressedair hose Ensure thatthe compressed air hoseisdisconnected fromthe compressed air source Fig 16 Compressed air maintenanceunit When required To drain th...

Page 25: ...o their initial position Conductor inserted incorrectly Insert the conductor straight The wire is stripped only of its insulation but not crimped Operating mode Only insulation stripping is set Change the operating mode to Standard setting 0 in Menu 3 The settings on the automatic ma chine do not match the associated sleeve Check whether the settings for sleeve cross section match the associated s...

Page 26: ... compressed air hosefromthe compressed air source Disconnectthe mainsconnector Open the frontpanel and place itdown carefully Caution Risk of injury fromsharp blades Use tweezersto replacethe blades Dispose of the removedbladesin aspecial container Note All fitted bladesmustbe replaced foreach cutter change Fig 17 Insulation stripping unit Remove both cams fig 17 item1 Allen key 2 5 mm Loosen the ...

Page 27: ...efasten the cover Fasten both camsso thatthey are located in position 0 Performan insulation strippingtest see section5 4 Performingthe insulation strippingtest 8 4 Replacing fuses Ensure thatthe automatic machineisswitched off Remove the mainsconnector Fig 19 Opening thefuse box Lever thefuse box fig 19 item1 with aflatscrewdriver fromthe mainsfilter unit Replace both fuseswith newones 2 x T2AH25...

Page 28: ...asbeen removedcompletely fromthe machine Remove the wireend ferrulereel Empty the waste container and replaceitin the automatic machine Close the frontpanel Pack the automatic machinein the original packaging The automatic machine isnowprepared fortransportand disposal if necessary 9 2 Disposing of the automaticmachine Decommissionthe automatic machineasdescribedin section 9 1 Decommis sioningthe ...

Page 29: ...10 Pneumatic diagram Rittal crimping machine R8 I We reserve the right to make technical modifications 29 EN 10 Pneumatic diagram ...

Page 30: ...11 Electric diagram 30 We reserve the right to make technical modifications Rittal crimping machine R8 I EN 11 Electric diagram ...

Page 31: ...11 Electric diagram Rittal crimping machine R8 I We reserve the right to make technical modifications 31 EN ...

Page 32: ...12 Conformity 32 We reserve the right to make technical modifications Rittal crimping machine R8 I EN 12 Conformity ...

Page 33: ...oftware Services 07 2021 D 0100 00000310 01 EN You can find the contactdetailsof all Rittal companiesthroughoutthe world here www rittal com contact RITTAL GmbH Co KG Auf dem Stuetzelberg 35745 Herborn Germany Phone 49 2772 505 0 E mail info rittal com www rittal com ...

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