Danfoss ET4500 Workshop Crimping Machine Instruction Manual

Danfoss ET4500 Workshop Crimping Machine

Product Information

Specifications:

• Manufacturer: UNIFLEX-Hydraulik GmbH
• Address: Robert-Bosch-Strasse 50-52, D-61184 Karben, Germany
• Phone: +49 (0) 60 39 / 91 71 – 0
• Fax: +49 (0) 60 39 / 91 71 – 181
• Date of revision: 2023-06-15
• Version: 1.0

Product Usage Instructions

Safety Instructions

Before using the machine, make sure to read and understand all safety instructions provided in the manual.

Start Screen

To begin, power on the machine and navigate to the start screen.

Crimp Using Workpiece Table

1. Access the start screen.
2. Select the workpiece specification based on your requirements.
3. Verify and adjust settings as needed before proceeding.

Control Settings

1. Log in with your user credentials.
2. Access the database for relevant information.
3. Manage data using a USB storage medium if required.
4. Edit crimping dies and administer users accordingly.
5. Adjust language settings and machine configurations as necessary.

Error Messages

If you encounter an error message such as ‘Oil filter contaminated,’ refer to the manual for troubleshooting steps.
Additionally, learn how to backup and restore CONTROL C.2 for data safety.

Annex

Refer to the annex section for information on accessories that can be retrofitted and a spare parts list for maintenance purposes.

FAQs

• Q: What should I do if I encounter an error message during operation?
  • A: If you see an error message, refer to the manual’s error messages section for guidance on troubleshooting steps.
• Q: How can I adjust the machine settings?
  • A: Access the machine settings section in the control settings menu to make necessary adjustments based on your requirements.

Imprint

Manufacturer:

UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50-52 D-61184 Karben Germany

Phone: Fax:

+49 (0) 60 39 / 91 71 – 0 +49 (0) 60 39 / 91 71 – 181

This Operating Manual of the machine is a translation; the original is in German.
Date of revision:2023-06-15 Version: 1.0
© Copyright by UNIFLEX-Hydraulik GmbH
Technical modifications reserved.
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

About this document

The control unit “Danfoss Control C.2” is consistently designated as control in this Operation Manual. This Operation Manual includes important notes on how you operate your machine and control safely, properly and economically.
1.1 Storage
This Operation Manual is a document also applicable in connection with the Operation Manual of the machine, therefore represents an integral part of the machine and must be kept available at the machine at any time. Upon disposal of the machine, the Operation Manual must also be handed over.
1.2 Figure presentation
Most figures have two areas: · Value setting (1) · General buttons for navigation in the menu bar (2) The individual elements in the figures are described from left to right and from top to bottom.

The values shown in the figures are given as examples and may differ from actual values – depending on the machine type and the individual selection in the basic settings.

If another user interface (*.xml file) is being used than the one described in the Operation Manual, the affected Operation Manual must be observed.

1.3 Abbreviations

PB PFC PFD PFM QDC UDL ULS UTS

Crimping dies Pressure Force Control (pressure joining), option Pressure/Force Display Pressure Force Monitoring (forming parameter monitoring) Quick die change system UNIFLEX Data Logging UNIFLEX Label System UNIFLEX Transfer Software

ICC UPMS

Industrial Crimp Calculator UNIFLEX Paperless Management System

1.4 Accessories
The machine may be fitted with accessories. A list of the available accessories is included in the Annex, Section “Accessories”.

Safety instructions

2.1 Presentation of warning notes

DANGER! WARNING! CAUTION! ATTENTION!

Warning notes in the Operation Manual warn against risks involved with the handling of the machine. Risk levels are identified as follows:
The signal word HAZARD identifies an imminent hazard resulting in serious injuries or death. This warning is supplemented by a triangular hazard symbol.
The signal word WARNING identifies a potentially hazardous situation, which might result in serious injuries or death. This warning is supplemented by a triangular hazard symbol.
The signal word CAUTION identifies a potentially hazardous situation, which might result in light injuries. This warning is supplemented by a triangular hazard symbol.
The signal word ATTENTION identifies a potentially hazardous situation, in which the product or property in the environment may be damages. This warning is supplemented by a hazard symbol or a exclamation mark.

2.2 Safety instructions

2.1 Use in compliance with intended purpose
This control unit is intended for industrial applications, only to be used to control the supplied UNIFLEX machine. Intended purposes include: · Operating temperature between 10°C and 45 °C; · Operation in a closed room. Use of the machine in compliance with the intended purpose also includes compliance with the instructions in this Operation Manual.
Use not in compliance with intended purpose Any other use is considered as not in compliance with the intended purpose, in particular:

· Manipulations of the control unit; · Use in explosive environments; · Use in the open air
WARNING!
Use not in compliance with intended purpose Use not in compliance with the intended purpose impose risks for life and health. Consequences resulting from use not in compliance with the intended purpose shall be under the sole responsibility of the owner. · Always use the machine in compliance with its intended pur-
poses.

Control description

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

(1) LAN socket to connect a network. Regarding options for connection to a network, please contact UNIFLEX.
(2) 2 x USB sockets (for the use of memory media/ accessories certified by UNIFLEX)
3.2 Foot pedal (accessory)
(1) Close machine pedal (2) Open machine pedal
WARNING!
Risk by fatiguing posture! A static posture may result in work-related musculosceletal disorders and reduce productivity. · Make sure that operators have sufficient periods of relief and
recreation.
3.3 Operation modes
The control provides for the following operation modes: · Manual operation
is activated in the control. The forming process is controlled manually via the buttons on the control panel or external buttons, e.g. the dual foot switch: ­ Buttons Close tool and Open tool . ­ Dual foot switch
The right foot switch is used to close the tool and activate

the forming process, the left foot switch is used to open the tool. ­ Depth stop The tool is closed automatically when the workpiece activates the depth stop by pressure. Press the button to open the tool. As soon as the forming diameter or forming pressure defined in the control is reached, the tool stops automatically. · Semi-automatic operation
is activated in the control. The forming process is started manually via the buttons on the control panel or external buttons, e.g. the dual foot switch: ­ Close tool button ­ Dual foot switch
The right foot switch is used to close the tool. ­ Depth stop
The tool is closed automatically when the workpiece activates the depth stop by pressure. As soon as the forming diameter or forming pressure defined is reached in the control, the tool stops and opens automatically.
Production is possible in any operation mode.
The operation mode selected before deactivating the machine will be active upon a restart. The operation modes are set on the control panel.
When the Foot switch button is activated, the Close tool button is inoperative, even if it is illuminated.

3.4 Control operation
The control features the following elements: · Buttons (blue circle) · Input fields (white field) · Value display (on grey background) The control is operated via the control panel: Tip on the relevant control element, · either with finger, or · with a suitable pointer.
ATTENTION!
Risk of damage to machinery! Hard objects or objects with sharp edges may scratch the screen surface. · Do not use any sharp-edged or hard objects to operate the
control.

If figures or letters have to be entered, a keyboard or number field showing the permissible range of values will be displayed after touching the control panel.

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

Crimp using workpiece table

5.1 Start screen
This screen is used to select the Danfoss product range from the list. Select settings from favourites. Select the product range Return to previous screen.

5.2 Select workpiece specification
This screen is used to select the hose type (workpiece) from the list. Confirm the highlighted workpiece. Return to previous screen.
By making an entry in the Filter field, the workpiece list may be filtered according to a specific criterion.

In this screen, you may select the matching coupling to the hose type (workpiece) from the two lists: · the nominal width is selected first; · subsequently a coupling matching the nominal width is selected.
Confirm the selected tool and continue in the next screen.
Return to previous screen.

In this screen, the steps for exchanging the crimping dies are shown. For more details regarding the replacement of the crimping dies, please refer to the machine Operation Manual.
The quick die change system has to be used to change the crimping dies.
The die wrench has to be used to change the crimping dies.
The crimping die set with the diameter shown here has to be used.
Return to start screen.
Return to previous screen.

5.3 Verify and adjust settings
Screen: Crimping die diameter Screen: Forming dimension diameter. Screen: Permissible tolerance of forming dimension diameter. Screen: Permissible ovality. Screen: Crimping field length. Screen: Crimping field length tolerance. Direct input of forming dimension via input field possible as an alternative. Display: current position of tool. Display: current value of forming pressure. Return to previous screen. Save current settings as favourites. Select settings from favourites.

The tool automatically opens after the forming process. The tool does not automatically open after the forming process. Enter additional settings (see following screen). Help (only if available, otherwise logo) Back to selection of product range.
Favourites even remain unchanged if the data are reloaded from a USB storage medium. Enter additional settings
Enter opening diameter. The current diameter at which the machine is set is accepted as opening diameter.

Only if automatic opening is active : Upon forming, the crimping dies remain on the workpiece until the machine opens them again (holding time).
Pre-select the number of workpieces to be processed. If “0” is entered, a deliberate number of forming processes may be performed without a message appearing.
Screen: Number of forming processes completed so far.
Return to previous screen.

Crimp without workpiece table

6.1 Start screen
The following control screen is opened by pressing the manual operation button:
Manual operation Semi-automatic operation Machine settings The figures are described in more detail in the Sections below.

6.2 Manual operation
This screen is activated to specify the settings for a forming process in the “Manual operation” mode.
Enter forming dimension diameter. The forming dimension diameter is the diameter to which the tool is adjusted. If a new forming dimension is entered, the set crimping die diameter is adjusted automatically. The crimping die table is searched for the next possible crimping die, which is smaller or equal to the forming dimension + 0.6 mm. Adjust the set forming dimension diameter upwards (+) or downwards (-) by 0.1 mm or with a figure value. Direct input via input field possible as an alternative. Enter the crimping die diameter into the control.

(Option) Crimping die thickness The symbol with the input field will only be displayed, if the use of special crimping dies is possible in the machine, and if the selected crimping dimension exceeds or is equal to the smallest possible special criming die.
Display: current value for the diameter.
Display: current value for the forming pressure.
The tool automatically opens after the forming process.
The tool does not automatically open after the forming process.
The screen for approaching the change position for crimping dies is opened. Please refer to “Change crimping dies” in Section 5.
(Option) Label printer
· Green display: automatic printing activated with every second forming cycle.
· Red display: automatic printing deactivated. · Activate button: The screen for the printer set-
tings is opened.
See “UNIFLEX Label System” (Option) in Section 5.
(Option) Industrial crimp calculator This is only displayed, if the machine is configured with this function and this function is activated in the machine settings. See “UNIFLEX Data Logging (UDL) and Industrial Crimp Calculator (ICC)” in Section 4.
Return to previous screen.

6.3 Semi-automatic operation
Form to a diameter. Form to a pressure value (only PFM and PFC). Load data record from database. Read data using a scanner (option). Return to Start screen. When the machine is switched from “Semi-automatic operation” to “Manual operation”, · forming to a diameter is activated; · pressure / distance limits are deactivated; · the holding time is set to “0” · the opening diameter is set to the maximum opening diameter.

6.3.1 Form to a diameter
Screen: Name of current data record. Touching: Load data record from database. The data record search function is case sensitive. Delete data record from input field. Enter forming dimension diameter. The forming dimension diameter is the diameter to which the tool is adjusted. If a new forming dimension is entered, the set crimping die diameter is adjusted automatically. The crimping die table is searched for the next possible crimping die, which is smaller or equal to the forming dimension +0.6 mm. Enter opening diameter. The current diameter at which the machine is set is accepted as opening diameter.

Adjust the set forming dimension diameter upwards (+) or downwards (-) by 0.1 mm or with a figure value. Direct input via input field possible as an alternative.
Only if automatic opening is active : Upon forming, the crimping dies remain on the workpiece until the machine opens them again (holding time). Manual opening during the holding time is possible at any time by pressing the button. Holding time = time interval in which the plastic forming of the material is completed.
Note, for PFC only: In order that the pressure is maintained and the crimping dies open automatically after the holding time, the button must remain activated for the entire holding time. If the button is released before the end of the holding time, the pressure will not be maintained, the crimping dies remain in their position and can only be opened manually by activating the button.
Enter the crimping die diameter into the control.
(Option) Crimping die thickness The symbol with the input field will only be displayed, if the use of special crimping dies is possible in the machine, and if the selected crimping dimension exceeds or is equal to the smallest possible special criming die.
(Only PFM and PFC) Data recordspecific customer setting: Pressure top limit not to be exceeded.
(Only PFM and PFC) Data recordspecific customer setting: Pressure bottom limit to be achieved as a minimum in order to achieve a correct forming.
Switches from closing to forming when the diameter of the pre-set unit is achieved. See below, “Set machine switch point”
Switches from closing to forming when the pressure of the pre-set unit is achieved. See below, “Set machine switch point”

Pre-select the number of workpieces to be processed. An appropriate message is displayed as soon as the selected number of workpieces is reached. If “0” is entered, a deliberate number of forming processes may be performed without a deactivation of the control.
Screen: Number of forming processes completed so far. Each forming process completed with the preset forming dimension diameter is counted. If the preset number is reached, the machine stops.
Display: current position of tool.
Display: actual position of the tool when the target value is reached.

Note:

@

Various mechanisms in the machine act on com-

pensating the spring back of the workpiece so that

the target value is reached. The displayed value

achieved may therefore deviate from the target

value entered.

Display: current value of forming pressure.

Display: actual forming pressure when the target value is reached.

Note:

@

Various mechanisms in the machine act on com-

pensating the spring back of the workpiece so that

the target value is reached. The displayed value

achieved may therefore deviate from the target

value entered.

(Option) Industrial crimp calculator This is only displayed, if the machine is configured with this function and this function is activated in the machine settings. See “UNIFLEX Data Logging (UDL) and Industrial Crimp Calculator (ICC)” in Section 4.

Only for HM 220 C and HM 225 C. Switches from slow pressing (tortoise) to rapid pressing (rabbit) and vice-versa. Slow pressing (tortoise) = 100 % pressing force. Quick pressing (rabbit) = 45 % pressing force.

The current data record automatically changes over to the next data record (subsequent data record).
Delete subsequent data record from input field.
The tool automatically opens after the forming process.
The tool does not automatically open after the forming process.
The screen for approaching the change position for crimping dies is opened. Please refer to “Change crimping dies” in Section 5. Save the displayed data under a name and add it to the database.
Note: Do not use any special characters for designation to prevent errors.
If a scanner is connected (optional), the data record may be activated via a barcode. (Option) Check forming result. See “Check with calliper” in Section 5. · Green display: automatic measuring after
forming is activated. · Red display: automatic measuring after form-
ing is deactivated. Proceed to the following screens: 1. Settings · Hose operating pressure · Counter See “Operating pressure and counter settings”, Section 4.
(Option) PFC only: 2. PID controller settings. See “Pre-set PID controller (PFC only)” in Section 4.

(Option) Label printer · Green display: automatic printing activated
with every second forming cycle. · Red display: automatic printing deactivated. · Activate button: The screen for the printer set-
tings is opened. See “UNIFLEX Label System” (Option) in Section 5.
Return to previous screen.
Set machine switch For machines with this option, the crimping dies are closed at two different speeds: · (rapid) Closing · (slow) Forming The switch point is set by the distance (mm/inch) or the pressure (bar/psi/MPa). The value reached by the machine first will trigger the switch from (rapid) closing to (slow) forming.
This setting has no effect in machines without this option.
Der U msc haltpunkt wird über den Weg ( mm/i nc h) oder den Druc k (Bar/Psi/M Pa) eing estellt. D er Wert, den di e M asc hine z uers t err eic ht, l öst das Umschalten von (schnell) Sc hließ en auf (langsam) U mfor men aus.
6.3.2 Form to a pressure value (only PFM and PFC)

Screen: Name of current data record. Touching: Load data record from database. The data record search function is case sensitive.
Delete data record from input field.
Enter forming pressure to be operated by the machine.
Enter opening diameter.
The current diameter at which the machine is set is accepted as opening diameter. Proportional share of the PID controller(only PFC). Regulates the oil pressure/oil flow. These settings must only be performed by qualified personnel.

Only if automatic opening is active : Upon forming, the crimping dies remain on the workpiece until the machine opens them again (holding time). Manual opening during the holding time is possible at any time by pressing the button. Holding time = time interval in which the plastic forming of the material is completed.
Note, for PFC only: In order that the pressure is maintained and the crimping dies open automatically after the holding time, the button must remain activated for the entire holding time. If the button is released before the end of the holding time, the pressure will not be maintained, the crimping dies remain in their position and can only be opened manually by activating the button.
Enter the crimping die diameter into the control.
(Option) Crimping die thickness The symbol with the input field will only be displayed, if the use of special crimping dies is possible in the machine, and if the selected crimping dimension exceeds or is equal to the smallest possible special criming die.
Travel distance top limit (referred to the die set) no to be exceeded.
Travel distance bottom limit (referred to the die set) to be achieved as a minimum in order to achieve a correct forming.
Switches from closing to forming if the diameter in mm is reached. See below, “Set machine switch point”
Switches from closing to forming if the pressure in bar is reached. See below, “Set machine switch point”

Pre-select the number of workpieces to be processed. If “0” is entered, a deliberate number of forming processes may be performed without a deactivation of the control. An appropriate message is displayed as soon as the selected number of workpieces is reached.
Screen: Number of forming processes completed so far. Each forming process completed with the preset forming dimension diameter is counted. If the preset number is reached, the machine stops.
Display: current position of tool.
Display: actual position of the tool when the target value is reached.

Note:

@

Various mechanisms in the machine act on com-

pensating the spring back of the workpiece so that

the target value is reached. The- value achieved

may therefore deviate from the target value en-

tered.

Display: current value for the forming pressure.

Display: actual forming pressure when the target value is reached.

Note:

@

Various mechanisms in the machine act on com-

pensating the spring back of the workpiece so that

the target value is reached. The displayed value

achieved may therefore deviate from the target

value entered.

(Option) Industrial crimp calculator This is only displayed, if the machine is configured with this function and this function is activated in the machine settings. See “UNIFLEX Data Logging (UDL) and Industrial Crimp Calculator (ICC)” in Section 4.

Only for HM 220 and HM 225. Switches from slow pressing (tortoise) to rapid pressing (rabbit) and vice-versa. Slow pressing (tortoise) = 100 % pressing force. Quick pressing (hare) = 45 % pressing force.

The current data record automatically changes over to the next data record (subsequent data record). An appropriate message is displayed.
Delete subsequent data record from input field.
The tool opens automatically after the forming process.
The tool does not automatically open after the forming process.
The screen for approaching the change position for crimping dies is opened. See “Crimping die replacement” in Section 5. Save the displayed data under a name and add it to the database.
Note: Do not use any special characters for designation to prevent errors.
If a scanner is connected (optional), the data record may be activated via a barcode. (Option) Check forming result. See “Check with calliper” in Section 5. · Green display: automatic measuring after
forming is activated. · Red display: automatic measuring after form-
ing is deactivated.
Proceed to the following screens: 1. Settings · Hose operating pressure · Counter See “Operating pressure and counter settings”, Section 4. (Option) PFC only: 2. PID controller settings. See “Pre-set PID controller (PFC only)” in Section 4.

(Option) Label printer · Green display: automatic printing activated
with every second forming cycle. · Red display: automatic printing deactivated. · Activate button: The screen for the printer set-
tings is opened. See “UNIFLEX Label System” (Option) in Section 5.
Return to previous screen.
Set machine switch For machines with this function, the crimping dies are closed at two different speeds: · (rapid) Closing · (slow) Forming The switch point is set by the distance (mm/inch) or the pressure (bar/psi/MPa). The value reached by the machine first will trigger the switch from (rapid) closing to (slow) forming.
This setting has no effect in machines without this function.
6.3.3 Operating pressure and counter settings

Hose nominal pressure input. It is only required to input the value, if the value indicated is to be printed on a label (see “UNIFLEX LAGEL SYSTEM ULS” in Section 5). For recording unit quantities, for instance, two vacant unit counters are available. The unit counters may be used independently. The counter reading may be modified manually by entering a value in the input field.
Reset counter reading to 0.
Return to previous screen.
(Option) PFC only: PID controller settings.
6.3.4 Load data record from database.

The control panel shows the database as a list of data records including names and forming data. The requested data record is selected by a touch and is then highlighted grey.
Name of data record
Forming dimension diameter
Forming pressure
Crimping die diameter
Opening diameter
Next data record
Filter data records according to the character string entered. Accept selected data record and change over to the production screen. Return to previous screen without accepting the selected data record.

6.3.5 Load data record using a scanner (option)
Scan the barcode using the scanner, or enter the barcode clear text manually. The scanned barcode is interpreted as the name of a data record. By accepting the scanned code, the data record table is searched for the appropriate name. If a data record with the same name is found, the related settings are loaded and the relevant screen for starting production is displayed. If the name is not found, an error message is displayed.
Delete scanned data. Accept scanned data and change over to the production screen. Return to previous screen without accepting the scanned data.
The codes processed by the scanner can be taken from the description enclosed to the scanner.

Control settings

The machine settings area is password protected. After the user has logged in, all screens may be opened one after the other.
7.1 User log in

xx_x.x

Enter user name. UNIFLEX default: user
Enter password. UNIFLEX default: user Screen: Total number Screen: Software version Screen: Active control panel Log in user and change to the first machine settings screen (database).
Return to Start screen.

7.2 Data base
The control panel shows the database as a list of data records including names and forming data. The requested data record is selected by a touch and is then highlighted grey.
Delete selected data record from database. Confirm the selected data and continue in the next screen. Return to Start screen. The user is logged off automatically.

7.3 Data management with a USB storage medium
The USB socket is located on the back side of the control console (to be used for storage media certified by UNIFLEX only).
Load data from an USB storage medium into the control. Load data from the control onto the USB storage The data upload from USB storage medium was successful. The data upload from USB storage medium was not successful, see error message.

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

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

No or other surfaces may be selected according to the specific layout.
7.5 User administration
In this screen, users may be created or deleted; in addition, passwords or the user level may be modified.
User name The user name consists of an alphanumerical string without spaces. UNIFLEX default: user Password UNIFLEX default: user User level:
0 Operator … Administrator (= fitter) Shows the user interface assigned to the respective user.

Selects the previous user, if any. Selects the next user, if any. Add user. Delete user. Save user data. Return to previous screen. Return to first machine settings screen (database). Proceed to next screen.

Creating a user

Select “Add user”.

Enter user name.

Enter password.

Select user level.

Save user data.

Successful saving is indicated by an appropriate message.

Delete user

Select user.

Delete user

User names
User names and the associated passwords are created or deleted by the operator. The user name currently logged on cannot be deleted. If

the current user name is to be deleted, it is necessary to log on another user first.
In the factory, the standard user “user” is installed as an “administrator”. The standard user can only be deleted if there is at least one other user name available on the administrator level.
The number of users is only restricted by the storage space of the control.
User levels
The user levels can be used to assign user names with different rights with regard to machine operation. In total, up to ten different user levels can be set up. The user level “administrator” cannot be deleted or changed.
At the factory, one administrator level is set up. The machine settings can only be called up by user names of the administrator level.
In the factory settings, the user levels “0 ­ 8” and “operator” have the same rights. These user levels are able to operate the full scope of functions on the machine but are not able to call up the machine settings.
The rights of the user levels can be programmed individually for an extra fee. Contact the manufacturer for this purpose.
The Administrator password may be required for repairs. If login data are no longer available, the user administration must be restored by the manufacturer subject to a charge.

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

7.6 Machine settings
Screen: Machine type Preset zero point and/or reference point of machine. Screen: Permissible range before zero point is reached, as from where the machine may build up force without causing damage to the bearing plates. The dimension depends on the geometry of the tool and cannot be changed. Screen: Outside the permissible range, the machine may build up a maximum pressure of x bar without causing the machine’s shutdown. This value cannot be changed. Maximum travel distance of the machine in millimetres. Definition of change position for crimping dies. Analog digital converter Converts the position encoder length in 0 ­ 27648 scale marks.

Analog digital converter Converts 0 – 400 bar in 0 ­ 27648 scale marks. The machine motor is switched off after expiry of the period set here. Diameter pre-setting: When a new forming diameter is entered, the diameter entered here is automatically added to the forming diameter and accepted as switch point. Screen: Number of forming processes up to this time. Pressure setting: When a new forming diameter is entered, the diameter entered here is automatically set for the forming pressure. (PFM and PFC only) Time in milliseconds after switchover during which the signal from the pressure sensor is ignored (damping). This is intended to mask out pressure peaks which may result by the first material contact.
Return to previous screen.
Return to first machine settings screen (database).
Proceed to next screen.
Restore default settings.
To the operating system. Closes the control software.

Instructions for action

8.1 Start-up control

1. Start the machine. The control operating system is started.
2. If the control CONTROL C.2 does not start automatically, double click on Uniflex (4) in order to switch to the CONTROL C.2. The Uniflex logo is shown before the first machine settings screen opens (database).
3. Set requested language (1).

Proceed to next screen.

5. Set requested units (2).

Proceed to next screen.

7. Select the appropriate control version by touching an *.xml-file (3).

Confirm entries.

The Uniflex logo is shown before the control start screen opens.

The Windows settings in Regional Settings must not be changed since otherwise the value tables are interpreted incorrectly.
8.2 Changing the crimping dies
In this screen, the steps for exchanging the crimping dies are shown. The quick die change system has to be used to change the crimping dies. The die wrench has to be used to change the crimping dies. The crimping die set with the diameter shown here has to be used. Return to start screen.
sd Dfe

Details of how to change the crimping dies can be found in the Operation Manual of the respective machine.
8.3 Check with calliper (Option)

The forming result including a freely selectable tolerance range may be checked by using a calliper. For this purpose, measure the workpiece at the point indicated by the triangle.
Current calliper value.

0021.91 mm

If the message “mm/inch? mm” is displaced, the pre-set unit of the calliper does not comply with the pre-set unit of the machine. Correct the measuring unit of the calliper or the machine.

If the message “Error mm” is displayed, no calliper is identified, or the communication between the cal-
liper and the control is disrupted.

Calliper settings. See “Pre-set calliper” in Section 5. Displays the relevant measuring points (front, centre, back). The recorded values are also saved in the UDL under their relevant letter (A – L).
Definition of the triangles: · Grey: outstanding measurement. · Red: point to be measured. · Green: point already measured.
Back to forming parameter screen.

or foot switch (1)

Accept measurement and proceed to next measuring point. Continue with measuring result screen after the last measurement.

The measured result in shown in the last screen:

Forming dimension diameter (preset dimension). Set correction value of forming dimension diameter.

Measuring result of the diameter as the mean value of the individually measured values. Rules: · Green display: the workpiece is within the per-
missible tolerance · Red display: the workpiece is not within the
permissible tolerance
The pre-set tolerance value is indicated behind the symbol.
Measuring result of the ovality as the mean value of the individually measured values. Rules: · Green display: the workpiece is within the per-
missible tolerance · Red display: the workpiece is not within the
permissible tolerance · Grey display: the measurements are not suffi-
cient (e.g. because only one measurement, each, was made in the front, centre and back).
The pre-set tolerance value is indicated behind the symbol.
Measuring result of the conicity as the mean value of the individually measured values. Rules: · Green display: the workpiece is within the per-
missible tolerance · Red display: the workpiece is not within the
permissible tolerance · Grey display: the measurements are not suffi-
cient (e.g. because only one measurement, each, was made in the front, centre and back).
The pre-set tolerance value is indicated behind the symbol.
Back to measurement screen to repeat the measurement.
Accept measurement and return to start screen.

8.4 Calibration
During calibration, the zero point and the crimping tool inclination are set. This is required i.e. if the slide bearing plates have been changed. The “Calibration” screen is found in the machine settings and is password protected. The process is shown in this screen and the next screen:
Select the UNIFLEX calibration mandrel with the indicated number. Insert crimping dies with the indicated size. Position the calibration mandrel thin end in the crimping tool and press the button. The machine reaches the calibration pressure.

Position the calibration mandrel thick end in the crimping tool and press the button. The machine reaches the calibration pressure. Display: calibrated zero point. Remove calibration mandrel: · Hold calibration mandrel and · Open tool with button.
Calibration was successful.
Calibration was not successful, repeat calibration process. Accept calibration and return to first machine settings screen (database).
The machine may also be calibrated by directly entering the zero point. See “Machine settings”, Section 4.

Error messages

9.1 Error message “Oil filter contaminated”

If an oil filter is used in the machine (depends on the machine type) and this filter is contaminated, an error message is displayed.

1. Replace oil filter in accordance with the instructions given in the Operation Manual of the machine.

2. Acknowledge error message by pressing the OK button in the message window.

button and the

The error message may also appear in the event of a low ambient temperature. Operate the machine in the idle mode for several minutes. If the message occurs again after restart, replace the oil filter.

If the error message is acknowledged without having replaced the oil filter before, the message will be displayed again when the motor is restarted.

9.2 Backup and restore CONTROL C.2
In the machine settings (password-protected area), you can switch to the operating system via the To the operating system button. Backup CONTROL C.2 1. Start StartCenter (6) by a double click.
The screen “Transfer” is opened, and the transfer is started. 2. Terminate transfer by pressing Cancel. 3. Activate the Settings button (4). 4. Start Service & Commissioning (1) by a double click. 5. Connect an empty USB storage medium (FAT32 formatted) to
the USB port of the control panel. 6. Select the Backup tab (3). 7. Confirm with Next.

8. Select Storage Card USB or Refresh to search for the USB storage medium again.
9. Confirm with Next. 10. Select Backup
It will only be possible to complete an error-free backup when Complete backup with licenses is selected.
11. Select complete backup with licenses 12. Confirm with Create.
The backup is created. This process can take some time. 13. Confirm the message Backup operation successfully completed
with OK. 14. Remove USB storage medium. 15. Restart the machine control by switching it off and on again at
the main switch.
Restore CONTROL C.2
1. Start StartCenter (6) by a double click. The screen “Transfer” is opened, and the transfer is started.
2. Terminate transfer by pressing Cancel. 3. Activate the Settings button (4). 4. Start Service & Commissioning (1) by a double click. 5. Connect the USB storage medium containing the backup file on
the back side of the control console. 6. Select the Restore tab (2). 7. Press the Next button. 8. Select Storage Card USB 9. Confirm with Next. 10. Select the requested backup file *.brf on the USB storage me-
dium 11. Select Restore 12. Confirm with Yes.
The restore process begins. This process can take some time. 13. Wait until the message Restore operation successfully comple-
ted appears. 14. Remove USB storage medium.

15. Confirm the message Restore operation successfully completed with OK.
16. The machine control is restarted automatically and is then ready for operation again.

Annex

Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part orders.

10.1 Accessories (retrofittable)

Accessories Double foot switch Calliper including cable and foot sensor Calliper including cable and foot sensor Calibration mandrel in set with PB (recommended for machine calibration) Pressure Force Monitoring UTS Software + Notebook bar code scanner ULS label printer with connection cable and software package ULS ribbon ULS label roll, green
ULS label roll, yellow
ULS label roll, blue
ULS label roll, brown
ULS label roll, purple

Part code PS.2 Double Calliper CtrlC 3 Inch Calliper CtrlC 4 Inch Calb CtrlC
PFM UTS CtrlC.2 BCR CtrlC ULS.2_C
888.469 507.1_CP Banderole 138 mm 507.1 XL_CP Banderole 292 mm 507.2_CP Banderole 138 mm 507.2 XL_CP Banderole 292 mm 507.3_CP Banderole 138 mm 507.3 XL_CP Banderole 292 mm 507.4_CP Banderole 138 mm 507.4 XL_CP Banderole 292 mm 507.5_CP Banderole 138 mm 507.5 XL_CP Banderole 292 mm

Only use original ULS coloured tape.

Please contact our Sales department for ordering accessories.
10.2 Spare parts list

Version 807.600

Position 1 2 3 4 5 6 7 8

Number 1 1 1 1 1 1 1 1

Version 807.700

Position 1 2

Number 1 1

Article number 807.710 807.374 807.066 800.061 800.060 807.068 800.063 800.062

Designation Control panel 800 mm C.2 with memory card Uniflex Touch Panel Emergency stop unit “Motor Start” button “Motor Stop” button Button: Foot pedal switching “Open” button “Close” button

Article number 807.710 807.374

Designation Control panel 800 mm C.2 with memory card Uniflex Touch Panel

Position
3
4 5 6 7 8

Number
1
1 1 1 1 1

Article number
807.067
800.061 800.060 807.068 800.063 800.062

Designation
Emergency-stop button, complete, as from approx. 10/2016 (date of production) “Motor Start” button “Motor Stop” button Button: Foot pedal switching “Open” button “Close” button

Standard cable length for control panel = 800 mm. Other cable lengths available: 1800 mm and 5000 mm.

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