TE Connectivity HV-CP Bedienungsanleitung
Customer Manual
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409-35011
12 JUN 20 REV C
SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................2
1. INTRODUCTION ..................................................................................................................4
2. SAFETY................................................................................................................................4
Standards.......................................................................................................................5
Ear and Eye Protection ..................................................................................................5
Safety Covers/Guards....................................................................................................5
Power Connections ........................................................................................................6
Safety Interlocks.............................................................................................................9
Emergency Stop (E-STOP) Switch ..............................................................................11
3. DESCRIPTION ...................................................................................................................12
Machine Overview........................................................................................................12
Specifications ...............................................................................................................12
Requirements...............................................................................................................13
Major Components.......................................................................................................14
Tooling .........................................................................................................................22
4. OPERATION ......................................................................................................................23
Overview ......................................................................................................................23
User Interface (UI)........................................................................................................23
Initial Startup ................................................................................................................24
Processing ...................................................................................................................26
5. MAINTENANCE .................................................................................................................39
Daily .............................................................................................................................39
Monthly.........................................................................................................................40
As-Needed ...................................................................................................................40
Preventive ....................................................................................................................44
6. TROUBLESHOOTING .......................................................................................................44
7. REPAIR AND REPLACEMENT .........................................................................................45
8. RECEIVING INSPECTION AND INSTALLATION .............................................................46
Receiving Inspection ....................................................................................................46
Installation ....................................................................................................................51
9. DECOMMISSIONING.........................................................................................................54
10. REVISION SUMMARY .......................................................................................................54
Semi-Automatic High Voltage Cable
Preparation Machine (PN 2335400-1)
ORIGINAL INSTRUCTIONS
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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye and ear protection while
operating equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Always ensure customer-provided power supply is
grounded to avoid electrical shock.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the power source when performing repair or
maintenance on the equipment.
Lock out electrical power when performing repair or
maintenance on the equipment
Lock out air supply when performing maintenance or
repair on this equipment.
Ensure that guards are in place and secure to
equipment.
Do not operate the equipment without guards in place.
Always disconnect air supply and then exhaust system
air pressure before performing maintenance or repair
on the equipment.
Use caution when working with this equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
Never use the machine for other than what it is
designed.
Never look directly into the internal machine light.
Bright light can damage the eye.
Never enter the electrical enclosure immediately after
turning OFF the machine power switch and
disconnecting the electrical power source. High voltage
electrical energy may be present in the electrical
enclosure. Read the warning label on the electrical
enclosure door before entering the system.
Pressure Release.
Caution –System may be pressurized.
IMPORTANT SAFETY INFORMATION
NOTE
Keep all decals clean and legible and replace them
when necessary.
DANGER
FIRE HAZARD
Do not use solvents or flammable liquids to clean the
machine. Solvents or flammable liquids could ignite and
cause serious injury or property damage.
CAUTION
Do not perform any service or maintenance other than
as described in this manual. Injury or damage to the
machine may result. Failure to observe these
precautions may result in injury or property damage.
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TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required. In addition,
Field Service Specialists are available to provide assistance in the adjustment or repair of the application
equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE SUPPORT CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person
familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many
difficulties can be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title,
telephone number, and extension)
4. Person calling
5. Equipment number (and serial number
if applicable)
6. Product part number (and serial number
if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that
may be helpful
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Figure 1
1. INTRODUCTION
This manual contains the safety, installation, setup, operation, and maintenance procedures for the TE
Connectivity High Voltage Cable Preparation (HV-CP) machine; PN 2335400-1, shown in figure 1. Throughout
this manual the left, right, and front side of the machine are defined as shown in figure 1.
The HV-CP is a semi-automatic, programmable, stand-alone machine designed to strip the cable jacket, braid,
and dielectric foil from round, multi-layer cables in preparation for the application of crimped terminals.
The machine can process cables with conductor cross-sectional areas ranging from 10mm2to 120mm2,
(8.8mm to 23mm outside diameter).
The machine and tooling have been designed to allow the processing of many cable types and sizes.
2. SAFETY
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.
Right Side
Left Side
Front
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Standards
The HV-CP machine:
Is designed to comply with the European Machinery Directive 2006/42/EU.
Is designed to comply with the European EMC Directive 2014/30/EU.
Ear and Eye Protection
Sound Level
The following applies to the sound level produced by the HV-CP machine:
The sound pressure levels at the operator position are at the infeed < 69.3 dBA, uncertainty K is
6.3 dBA. The sound power level is 74.0 dBA, uncertainty K, 7.4 dBA.
NOTE
Operating conditions and procedures during sound testing are in accordance with EN 1218-4:2004 + A2:2009. Sound
pressure level at the operator position have been measured in accordance with EN ISO 11202:2010. The sound power level
has been determined in accordance with EN ISO 3746:2010. Uncertainty has been determined in accordance with EN ISO
4871:2009.
Protection
Eye and ear protection must be worn at all times when operating or servicing this machine.
Figure 2
Safety Covers/Guards
DANGER: Operating the machine with missing or removed components may result in moderate or
severe injury, including death.
All safety guards and doors must be in place and securely closed before operating the machine.
Figure 3
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Power Connections
Main Electrical Power Disconnect
The main electrical power disconnect switch is located on the left side of the machine. The switch may be
locked in the “OFF” position,Lock Out/Tag Out (LOTO), to provide a safe condition for maintenance or
repair by inserting a padlock (not included) into the locking locations (see Figure 4).
DANGER: Never enter the electrical enclosure immediately after turning OFF the machine power switch and disconnecting
the electrical power source. High voltage electrical energy may be present in the electrical enclosure. Read the warning label
on the electrical enclosure door before entering the system.
Figure 4
Lock Out/Tag Out
Main Switch in
OFF position
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Pneumatic Connections
1. Pneumatic Power Disconnect
A manually operated main air disconnect valve is located on the left side of the machine, below the
main electrical power switch. The main air valve will exhaust all residual air from the machine when
turned from the Supply (SUP) position to the Exhaust (EXH) position. The valve may be locked in the
EXH position (Lock Out/Tag Out) for maintenance or repair, by inserting a padlock (not included) into
the locking locations (see Figure 5)..
Figure 5
Lock Out/Tag Out
Main Switch in
EXH position
Main Air
Disconnect Valve
in
SUP position
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2. Airlock Valve
If the incoming air supply volume is inadequate, the cable grip force could be reduced during the
vacuum cycle. The airlock valve is designed to improve the performance of the machine by
maintaining the grip pressure at all times (see Figure 6). It also allows the cable grip to be released, if
the guard door is opened and the red button on top of the airlock valve is depressed.
Figure 6
Airlock Valve
Airlock Valve
Pressure
Release Button
(Red Button)
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Safety Interlocks
The machine has two safety interlocks; one located under the sliding Top Guard at the front-left corner of the
chassis (see Figure 7) and one located at the top-left inside corner of the Scrap Door (see Figure 8).
Sliding door Interlock
The interlock located under the sliding Top Guard (see Figure 7) is monitored by a dedicated safety relay.
When the Top Guard is opened, the four servo-motor axes will be disabled thru an STO (Safe Torque Off)
function (where the drives are still energized but their motor outputs are disabled) and the machine air
supply will be turned “OFF” and residual air pressure will be exhausted. Together, this effectively stops all
machine motion. When the Top Guard is closed, if the Emergency Stop relay is energized, the Interlock
safety relay will automatically re-enable the STO outputs and reapply air pressure.
CAUTION
The machine air supply to the valve controlling the scrap vacuum remains energized when the interlock is interrupted.
Disconnect and “Lock Out/Tag Out” the main air supply when performing maintenance or repair.
Figure 7
Top Guard Interlock Closed
Top Guard Interlock Open
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Scrap door Interlock
Interrupting the scrap door interlock (see Figure 8) does not cause the disabling of the servos or the
dropping of air pressure but disables air to the vacuum system.
CAUTION
it is not advisable to open and/or empty the scrap bin while a cable prep cycle is in process.
NOTE
Resetting an interlock will not automatically re-start the machine.
Figure 8
Scrap Door Safety Interlock Open
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