PAL 300x - Operation Manual – Version 2.1.

PAL 300x

Version 2.1.8
OPERATION MANUAL
Testing Tool
Analyser Software

Date: 29.09.08 Version: 2.1.8

Created: J. Windorfer Checked: P. Schwarz
File: BA_Pal300x_EN.doc
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PAL 300x - Operation Manual – Version 2.1.8

Contents
1 Safety Regulations for Electrical Machines in Industrial Use ............................................................. 3
2 Scope of supply ................................................................................................................................. 4
3 Principal Operation ............................................................................................................................ 5
4 Safety notes....................................................................................................................................... 5
5 Operating elements and connectors .................................................................................................. 6
6 Installation and Maintenance ............................................................................................................. 6
6.1 Installation .............................................................................................................................. 6
6.2 Maintenance .......................................................................................................................... 7
7 Operation with the PAL300x .............................................................................................................. 7
7.1 Switching on/off ...................................................................................................................... 7
7.2 Operating modes:................................................................................................................... 8
7.3 Adjusting a press.................................................................................................................... 9
8 The press analyzing software .......................................................................................................... 10
8.1 Overview (Screenshot)......................................................................................................... 10
8.2 Data management (creating a new project) ......................................................................... 12
8.3 How to setup a press test..................................................................................................... 14
8.4 Loading a reference curve ................................................................................................... 18
8.5 Printing the results ............................................................................................................... 19
8.6 Additional software features ................................................................................................. 24
9 Calculation of the “critical machine capability” index ....................................................................... 34
10 Installing the PCMCIA expansion card ............................................................................................ 35
11 EU Declaration of Conformity .......................................................................................................... 40

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PAL 300x - Operation Manual – Version 2.1.8

1 Safety Regulations for Electrical Machines in Industrial Use

Danger

Electrical machines are equipment for use in industrial plants. During operation of the machine dangers
may arise through rotating and/or voltaged parts.

In case of improper use of the machine during commissioning, operation and maintenance severe
injuries to persons and damage of property may arise. The machine may only be used under the
provisions stated in the instruction manual, additionally the local working conditions should be
considered.

Warning

• Authorized and qualified specialist staff may only carry out transportation, installation,
commissioning, electrical connection, operation and maintenance.
• Knowledge of the regulations for the prevention of industrial accidents and first aid measures is
a prerequisite for safe and trouble-free operation of this system.
• This instruction manual contains the most important notes for operation of the system in
accordance with safety requirements.
• All the persons working with the system must observe this instruction manual and especially the
safety notes contained herein.

Non-observance is a safety risk!

Our “general sales and supply conditions” always apply as these are available to the user under
www.cable-tec.net at any time. Any claims for warranty or liability in case of personal injury or property
damage are excluded, if they can be traced back to one or several of the following causes.

• The equipment was not used according to the intended purpose.

• Improper installation, commissioning, operation, and maintenance of the equipment.
• Operation of the equipment with defective safety devices or with improperly mounted or non-
functional safety and protection devices.
• Non-observance of the information in the operating instructions concerning installation,
commissioning, operation and maintenance of the equipment.
• Unauthorized modifications of the equipment.
• Repair work performed improperly (no original spare parts) by unauthorized personnel.
• Events caused by the effect of foreign bodies and force majeure.

Service telephone

In case of breakdown of the machine or in case of danger please call our service hotline :

Tel. +49 (0) 8554 94 23 9-0, Fax + 49 (0) 8554 94 23 9-20, eMail info@cable-tec.net

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2 Scope of supply

1. Sharpening stone to clean of the contact area 8 PCMCIA – extension card

for the PAL in the crimping press 9. PAL 300x main unit
2. Space for screws for the crimp height adaptor 10. A set of cable including:
3. Space for crimp height adapter to suit other Cable for:
crimp heights (Tyco Yazaki) • Providing connection to a CFMX
4. Slide feed for changing crimp force crimp force monitor
5. Relay box for automatic press triggering • Connecting PAL with a computer
6. Slots for crimp height adapters (Tyco Toyo) • PCMCIA extension card
with pressing plates 10 mm, 65 mm, 70 mm 11. Battery charger
7. Driver for the PCMCIA – extension card

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3 Principal Operation
The PAL 300x is a tool to adjust and monitor crimping machines (automatic or hand working stations).

The PAL 300x includes two “devices in one housing”.

It can operate as a digital height gauge to adjust the lower dead point of machines under real time
dynamic conditions.

It can monitor the capability of the crimping machines in connection with a PC to get detailed
information, like the shape of the force curve, the CMK values of the machine and a printout of these
results.

The PC program of the PAL can include the signals of external crimp force monitoring device, and so
the whole crimping system can be monitored.

The PAL300x is powered by either an external power supply or by an internal rechargeable battery.

The PAL system includes the measurement device and the PC program, which evaluates the data and
stores them in a database.

4 Safety notes

• Knowledge of the basic safety notes and safety regulations is a prerequisite for safe and
trouble-free operation of this system.
• This instruction manual contains the most important notes for operation of the system in
accordance with safety requirements.
• All the persons working with the system must observe this instruction manual and especially the
safety notes contained herein.
• In addition, all the rules and regulations for accident prevention and environmental protection
applicable at the respective location must be strictly observed.

Any claims for warranty of liability in case of personal injury or property damage are excluded, if they
can be traced back to one or several of the following causes:

• The equipment was not used according to the intended purpose.

• Improper installation, commissioning, operation and maintenance of the equipment
• Operation of the equipment with defective safety devices or with improperly mounted or non-
functional safety and protection devices.
• Unauthorized modifications of the equipment.
• Repair work performed improperly (no original spare parts) by unauthorized personnel.
• Events caused by the effect of foreign bodies and force majeure

Important!
Use according to the intended purpose also includes:

! • Observance of all the information from the operating instructions

• Observance and performance of all inspection and maintenance work
Non-observance is a safety risk!

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5 Operating elements and connectors

8 1. On / off key
9 2. Teach in key
7 3. Wheel to lift the PAL
4. Connector for serial
10
interface
6 5. Connector for power
11 supply / battery charger
5 6. Connector for relay to
simulate a foot switch
7. Indicating light to show
4 whether the relay is
active
8. Pressing plate for force
and height measurement
9. LED bar graph for force
and height
3 10. Scale for force
12 measurement
11. Scale for height
2 measurement
12. Level for changing the
force of the internal
1 springs and for switching
between the static and
dynamic mode

A relay box is shipped with the PAL to connect with Plug (6). After connecting the relay contact parallel
to the foot switch (starter contact at automats) the press can be triggered by the PAL 3001

6 Installation and Maintenance

6.1 Installation
To test a press the PAL 300x has to be mounted instead of an applicator:

When mounting the PAL 300x in the press pay attention to the instructions and
! safety notes of the press producer concerning the installation of an applicator!

1. Remove the applicator from the press. Observe therefore the safety notes from the press
producer.
2. Put the PAL300x in the press on the applicators place and mount it on the base plate according
to the hints of the press producer (installation of an applicator).
3. The pressing plate of the PAL300x must not connect mechanically with the press ram! The ram
must not apply any pull force to the analyser.

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4. When using the PAL300x to trigger the press the relay box (3) has to be connected with the
cable (1) to the analyser. The relay contact (blue jack) has to be connected parallel to the foot
switch (2) of the press.

1
3

5. Connect, if necessary, Your PC with the RS232 interface cable.

6. Make sure that no cable is touching a moving part of the press or is lying between the ram and
the pressing plate of the analyser.

6.2 Maintenance

In general the device is maintenance-free.

But it has to be sent to the producer for inspection and adjustment before the lapse of the date on the
test badge.

7 Operation with the PAL300x

7.1 Switching on/off

To switch on the device press until the green light gets on (after 2 seconds). After releasing the key
the initialising procedure is running (showed by the lights running from bottom red to top red of the LED
bar).
The device is now ready for teach in new sample curves (showed by the blinking green LED)

To switch off the device press until the bottom red LED from the bar is switched on. After releasing
the key the power is switched off.
The PC program can switch off the device either by clicking the “off” button or by closing the program.

When the device is not in use longer than 10 minutes it switches off automatically. Not in use means no
serial communication, no curve is measured and no key is pressed.
When the battery is discharged, the device makes a defined switch off, to prevent wrong actions caused
by low voltage.

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7.2 Operating modes:

Two operating modes are available:

1. Static height measurement:

In this mode the PAL is working as a micrometer screw the ram can be moved down slowly and the bar
graph displays the height of the lower dead point of the ram. In this mode the device is working in a
static mode. The force cannot be displayed, because the force sensor has dynamical characteristics.
In this mode there is no communication with PC.
To get in the static mode the lever (12) has to be pushed in the “free spring” position.
In static mode the LEDs of the bar are switched off every 2 seconds for a short time. To leave the static
mode pull the lever (12) to one of the 4 positions where the spring is activated. The device is then in
dynamic mode and ready to teach in.

2. Dynamic force and height measurement:

In this mode the force and height signals were measured in real time. The curves are stored in internal
memory and then sent to the PC where they are displayed.
Before curves can be sent, the maximum force and the duration of a curve have to be measured and
with this information the optimum gain and sampling rate can be calculated.
This all happens in the teach in procedure.

Teach in:
After power on, after leaving the static mode or after pressing more than 2 seconds the device is in
the dynamic teach in state, recognizable by the blinking green LED. Now the device is waiting for
sample curves to adapt the gain and the sampling rate and to get a reference curve.
When this curves are measured the data are sent to the PC, and the device gets into the normal
dynamic running state.

Running:
Every incoming curve is stored and its maximum is computed. The stored curve and the results will be
sent to the PC, the maximum of the curve is displayed on the bar graph.
Normally the deviation from the optimum height is displayed. To switch between force and height
display press (a short time, because a long pressing would cause the entering of the teach state).
When force is displayed, the lights are constant on. When height is displayed the lights are switched off
for a short time every two seconds.

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7.3 Adjusting a press

Coarse adjustment:

Important!
The coarse adjustment with free springs is necessary to avoid mechanical damages
! of the press or of the PAL!
Do not start the fine adjustment with activated spring load when You not exactly know
the height of the lower dead point of the press!

1. Replace the applicator by the PAL and switch on the PAL (by pressing until the green LED
is lightening).
2. Push the lever (12) in the innermost position (“free spring“ position). The Pal is running in the
static mode.
3. Make a slow press cycle (depending of the press type by hand or with step keys).
4. Adjust the press height until the upper yellow and red LEDs in the bar graph are blinking after
each cycle.

Press height too low. Press height too high Press height ok for
fine adjustment

Fine adjustment:

1. After coarse adjustment of the press pull the lever (12) on one of the four positions where the
springs are activated.
2. The PAL switches automatically in dynamic teach in mode.
3. Make two fast press cycles to give the PAL samples needed to compute parameters for optimal
measurement of the signals.
4. After the third cycle the deviation of the optimum height is displayed (similar like in slow mode).
5. Adjust the press height until the green LED in the bar graph is shining after each cycle.

Press height too low. Press height too low

Press height ok

With a good press after every cycle the green LED should shine.
With pressing the key the deviation of the applied force can be monitored. Even here always the
green LED should blink.
For detailed information and for statistical purposes connect a computer with the serial interface and
start the PAL software (see below)

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8 The press analyzing software

8.1 Overview (Screenshot)

26 28
25 27

23

22 A B
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21

20

24
19

18

17
16
15
14
13
12 30 33 34
11
10
9
8 31
7
6
5
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3
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Elements and buttons:

1. Button for creating a new project

2. Button for opening or creating a new project
3. Button for saving current session data
4. Button for opening the printing dialog
5. Button for saving current session data as PDF-file
6. Teach in button
7. Button for calibrating the external crimp force monitor
8. Relay Box configuration button: a number of press trigger events can be predefined
9. Stops execution of press trigger events
10. Starts execution of press trigger events
11. Executes one time trigger event
12. Starts automatic COM port search for either PAL or external crimp force monitoring device
13. Stops automatic COM port search
14. Opens a note pad for adding some additional measurement information
15. Opens a message box containing information about the PAL
16. Button to get information about revision number and manufacturer
17. Slide bar for selecting a range of data displayed at the measurement value history. The data
can be load or measured.
18. Double click opens dialog to change PAL settings
19. Indicating PAL state (PAL can be disabled by double click)
20. Battery state (charging battery indicated by progress bar slow motion)
21. Load button gives possibility for loading already stored session data
22. Double click opens dialog to change settings of the external crimp force monitor
23. Indicating state of external crimp force monitor (crimp force monitor can be disabled by double
click)
24. Shows specification limit1
25. Peak value measured for actual event1
26. Average of the maximum measured value1
27. CMK value including CMK limit in brackets1
28. CM value1
29. Shows the actual press event (graph, peak value, average value, CM, CMK – value and CMK –
limit
30. History of height data measured by the press analyser
31. Upper specification limit (calculated automatically after teach in phase)
32. The axle scale derived by reference value (teach in) and the specification limits
33. History of force data measured by the press analyser
34. History of force data measured by the external crimp force monitoring device

1 Accordingly applies the same in area A and B. In A is shown the reference force and in B the external crimp force monitor

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8.2 Data management (creating a new project)

All received data of the PAL device and crimp force monitor are stored in a database. This
database is Microsoft Access type and named projects.mdb.

After starting the program a window is Normally a project is related with an

opened where an existing project can existing crimping machine. For every
be loaded or a new project can be machine a project should be created.
created.

After clicking the “New" button the name of the press, an identity number and a description
has to be entered.

Enter a user defined project

name

Press Identification number

unique to each press

If necessary one can enter a

short description.

Select the PAL–device used If available select type of Device button opens a dialog
for analysing press. external crimp force for managing devices (adding,
(PAL 300x can be used in monitoring device. deleting etc.). (Index 8.6,
case of unknown PAL – type. managing hardware devices)

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In the Project list the name, the

description and the Press ID for each
Project is displayed.

After a mouse click on project item the

project name and the date of the last
modification is displayed again in the
bottom of the window.

Each project can store a set of curves (sessions). This set represents a quality test of the
actual machine. Every set of curves can be loaded and directly compared with the actual
curves coming online from the PAL device.

All sessions are listed after

clicking the + sign in front of the
projects name.

Name and date of the last

modification are shown together
with the number of curves (in
brackets).

• Project parameter settings

For each project parameters like relay cycles, CMK limits, specification limits etc. can be
entered. For each new project default Values are used, but they can be overwritten by
project specific parameters. Select
„Options“
„Parameters“, to enter the parameters.

After selecting menu:
„Options“

„Parameters“ the window for
the CMK specific is opened.

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Here can be entered all needed parameters for the CMK calculation of a machine capability
test. For more details see Calculation of the “critical machine capability” index.

The press analyser settings can be

changed in the options menu.

Selection of the serial RS 232 port

for the press analyser.

Selection of event period and

number of events. (The PAL trigger
relay is needed)

Information about PAL firmware

release and remaining crimp cycles
for PAL.

Updating press analyzer firmware.

Not available at present.

8.3 How to setup a press test

8.3.1 How to make a press – test with the press analyzer only

This guide helps you step by step to get more familiar with the PAL - software. It shows how to set up a
new Project and to set up the connections to the different press analysing devices. The screenshots,
which belong to the different steps, are also shown.

• After setting up a new or open an existing project, the program will try to connect both the PAL
device and the external crimp force monitor

Status: no device is connected

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• Deactivate the external crimp force monitor

Crimp force monitor status

display change to “disabled”.

• Set up the PAL

The first method is to change the settings manually:

Select the COM port corresponding

to the press analyzer.

The second method is easier to use:

Press “Find COM” button for
automatic PAL setup. If PAL is
found, press “Stop COM”.

• With establishing the connection, the PAL state should change to “teach-in”

The PAL is ready for teach – in.

• Start triggering press cycles to adjust internal PAL parameters. At least up to 3 crimp cycles
needed.

Now the PAL is in learning –

mode.

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• After teach in phase the PAL is ready for sampling data.

Now the PAL is in running –

Mode.

• Save the collected data, by clicking the “Save” button in toolbar or the menu item

„Sessions“
„Save“

Enter a suitable name for the

current session.

Remark: If connection to the device is lost

or the teach button is pressed, the session
will be ended and the save dialog
automatically appears.

8.3.2 How to make a complete press - test, using a PAL together with an external crimp force
monitor

• Activate the external crimp force monitor (in this setup a CFMMX is used)

Left click the menu item

“Options”
“CFM MX”

“Enabled”

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• Setup the external crimp force monitor connection

As already shown in the PAL setup two possibilities are given for setting up a
communication. Here just one method is explained in more detail. For using the second
more easy method see 8.3.1.
Enter a proper device name.

Select the proper force sensor

channel.

Enter the Machine ID

corresponding to the CFM MX
(available in the system – menu
of the CFM MX device)

Select the COM port and speed

used for device communication.

If necessary enable „use

network connection“. Enter the
correct IP address and port
(available in the LAN – menu of
the CFM MX device).

• With establishing the connection of both devices, the PAL state and the external crimp force
monitor state should change to “teach-in”
PAL and CFM MX state bar
indicating system in teach -
mode

• Change the automatic trigger function settings

Click the red-circled button to
open “Device Relay Settings”
dialog

Trigger period and number of

trigger events can be set.

• Left click of the start button Activates automatic trigger function

Remark: Automatic trigger function is for

use only with the external relay box.

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• Press starts crimping

PAL and CFM MX state bar

indicating system in teach -
mode

• Sampling data

PAL and CFM MX state bar

indicating system running -
mode

8.4 Loading a reference curve

After selecting a session and clicking OK the project is opened and the session is loaded as comparison
(index 8.2, open a project). When the project name is selected with “OK”, the project is opened and the
last modified session is loaded automatically as comparison. When a project is already open it is
possible to load another set of the projects sessions.
Click
„Curves“
„Compare curves“
„Load“ to get the screenshot.
In this window additional information like sampling rate gain of the press analyser and a preview of the
shape of the reference curve are displayed.

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The data are organized as shown below

projects.mdb

KMI KN20 KMI KM3010 Device xy

Reference Reference Reference
Qual Test

Qual Test

Qual Test
Curve 1 Curve 1 Curve 1
Curve 2 Curve 2 Curve 2
No 1

No 1

No 1
Curve n Curve n Curve n
Reference Reference Reference
Qual Test

Qual Test

Qual Test
Curve 1 Curve 1 Curve 1
Curve 2 Curve 2 Curve 2
No 2

No 2

No 2
Curve n Curve n Curve n
Reference Reference
Qual Test

Qual Test
Curve 1 Curve 1
Curve 2 Curve 2
No 3

No 3
Curve n Curve n

8.5 Printing the results

There are three kinds of printing the results selectable.

1. The history of peak values printed as bar diagram (similar as shown on the screen
2. The shape of the last measured curves
3. The history of peak values listed alphanumerical
4. The Gaussian distribution
5. All data can be printed at once by checking the “Print all… “ – Option.

On each hardcopy the results of the actual and of the last test are displayed. (Notes added by the
user will be attached automatically on the printout.)

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Sample print out of “History of peak values”

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Sample print out of “Actual Curves”

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Sample print out of “Statistics”

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Sample print out of “Gaussian distributions”

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8.6 Additional software features

• Notes (14):
„Sessions“
„Notes“

If required, additional information can be attached to the measurement session.

• Device info (15):
„Options“
„PAL 300x“
„Informations“

By clicking the device – info – button (15) a message window appears. The window
contains information about the firmware version used by the PAL and the remaining number
of trigger events before the PAL have to calibrate new.

• Change Language settings:
„Options“
„Language“

As system language can be chosen

English or German.

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• Units:
„Options“
„Units“

It can be used the European (millimetre

and kilo Newton) and the American Unit
(inch and pound). The print size of
100% corresponds ISO A4

To insert a logo double click on the

white area

• Managing hardware devices:
„Options“
„Hardware“

The second way to open the hardware devices, open the project dialog and select
“Devices”.

Device managing dialog: create new

devices, remove or change existing
devices.

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Create a new device (Select “New”)

Select PAL device type

corresponding to the
used PAL.

Select „New“. A dialog appears where the Change communication port. If required
device settings can be changed. enable network connection and select IP
network address.

Create a new CFM MX(N) device. The procedure is similar to new PAL device creation.

Select CFM MX(N)

Select CFMMX for serial device if a CFMMX
interface communication with network option is
used.

Select channel number

used for force sensor. Select channel
number used for
force sensor.
Change Machine
Identification number. Change Machine
Identification number.

Change COM Port

number and Change network IP
communication speed. address and Port
number.

If more then one device is used its recommended to create a separate device in the PAL –
software one for each device. Additionally enter a suitable number and serial number.

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• Reducing database size:
„Project“
„Compact Database“

With every measurement the database

size will increase. Therefore it is
recommended to reduce size.

• Select path for external database location:
„Project“
„Set Database location“

Normally is the database location in the

installation listing of the PAL software, but you
can select an external database location.

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• Export projects and sessions to new empty database:
„Project“
„Export Database“

Exporting projects to an empty database might be useful i.e. if data should be sent via e –
Mail for further analysis.

A file dialog will appear to

choose location and name
of the new database.

Select the projects and the

sessions to be separated.

The time for exporting a database depends on the number of project and sessions. This
may take several seconds. A progress bar during export will give more information.

• View external projects and session.
“Project”
“View external Database”

This item is used for opening an exported database in read only mode. In this mode neither
the stored data can be changed nor a device can be selected (devices are offline).

Select menu:
„Project“

„View export Database“

This window opened, after

de menu item will be
chosen

Open a session of the project

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After data inspection the

database should be closed
again.

• Save data as picture or PDF – document:
Project“
„Save as JPEG“

„Save as PDF“

This item provides possibility to save sampled data as picture or PDF-file.

Select menu
„Project“

„Save as JPEG“

Select one of four data type

to be stored as JPEG

For saving data in a PDF – Document

select menu:
„Project“
„Save
as PDF“ then select one of four data This PDF – document including
type. all data type in one file.

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• Export data to excel:
„Project“
„Export to Excel Sheet“

For further analysis data can be stored in an Excel – file.

For export data to excel select

menu:
„Project“
„Export to
Excel Sheet“

Example for Excel export of session

data.

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• Inspecting the curve shape

It is possible to increase each curve by double clicking the displayed little curve. So it is
possible to examine and compare the shape of the actual curves for example with the
shape of the loaded curves from a recent test.

• Enhanced statistical data analysis

The trend of data from the first up to the last crimp can by analyzed and compared within
statistic windows.

Add a statistic window

Add a statistic window by selecting
menu:
„Window“
„Statistic
Window“
„Add Statistic Window“

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After clicking, a blank Window

appears

Within this window different

types of data can be displayed
by enabling the corresponding
check – items.

It is possible to display different

types of data in parallel (i.e. PAL
– force and CFMMX – force).

The different types of data can

be displayed in respect to the
same scale (possible only for
data using the same unit).

Another sample with CMK

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• Calibration of the CMF MX (external device)

A crimp force monitor can work with different force sensors mounted in the RAM, the base
plate or on the frame of the press. According to this normally never the real peak force will
be displayed by the CFM.
With the PAL the CFM can easily calibrated to display the real force.
1. Start Teach in and make crimping cycles until the states of both devices (PAL and CFM
MX) show „running“ and the curves are displayed on the screen.
2. Normally there is a difference between the maxima of the PAL force curve (1) and CFM
MX force curve (2).
3. After clicking the calibration button (3) the CFMMX Peak – Force – Window is shown.
4. With clicking the OK button the automatically calculated value will be sent to CFM MX.

- PAL 300x: Force measured by the PAL

- CFMMX Max-Force: CFM’s previously
4
displayed force value
- New Max-Force: The value which would be
shown by using the New Peak value. Changing
the New Peak value by hand will lead to an
automatic change of the New Max-Force value.
- CFMMX Peak: Old calculation factor for the
CFM force displaying.
- New Peak: automatically calculated factor
(using the difference of PAL Max-Force and
CFMMX Max-Force).

Important!
Do not operate the CFM with the keys. The PAL program will always force the CFM

! into operating mode. All needed steps for testing are made automatically by the PAL
program. When you want to change some settings of the CFM you have to disable
the device in the options menu.

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PAL 300x - Operation Manual – Version 2.1.8

9 Calculation of the “critical machine capability” index

To calculate the CMK for the force, a reference peak value is needed.

The first cycle after teach in are measured and the peak relates the teach peak (TP)

Then the upper and lower specification limits are calculated with the specification limit of force (SL_f) in
percent, entered by the user in the setup menu:

 SL _ f [%]   SL _ f [%] 
USL = TP ⋅ 1 +  LSL = TP ⋅ 1 − 
 2   2 

These Values are displayed in the history diagram ((26), (27) and (28))

For all following curves the average of the peak values and the standard deviation is calculated:

Average =
∑ Peak[i] sd =
∑ (Peak[i] − Average) 2

Count Count − 1

And with this values the machine capability is calculated:

USL − Average Average − LSL

CMK 1 = CMK 2 =
3 ⋅ sd 3 ⋅ sd

The lower value of this both results is finally used as CMK: CMK = Min (CMK1, CMK2)

USL − LSL
CM =
6 ⋅ sd

The calculation of the CMK concerning the height measurement of the lower dead point of the press is a
little bit different:
The reference height is already known (normally 135,8mm) and has not to be found out of the first
curves: The USL and LSL are calculated with the values the user has entered in the setup menu:
These values are Optimum height (OH) in mm and specification limit height (SL_h) in µm:

specification limit height (SL_h) [µm]

SL _ h [mm] =
1000

SL _ h SL _ h
USL = OH + LSL = OH −
2 2

The rest of the calculation is identical with the force.

Sd
PN (PressNoise) = 100 ⋅
Average

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PAL 300x - Operation Manual – Version 2.1.8

10 Installing the PCMCIA expansion card

Mobile usage of the PAL300x with a Notebook can gain some advantages. For example extended data
analysis is possible.
For connecting the PAL with your notebook a type RS232 serial interface must be present. In case of
missing such an interface a PCMCIA card comes with the PAL300x.
After installation two RS232 interfaces should be available at your Notebook. The second interface can
be used with a crimp force monitor (CFM MX), which provides you more comprehensive analysis
options.
Please follow the following steps for installation.
Switch off your notebook and insert the PCMCIA extension card. After rebooting your notebook the
operation system should report a new hardware device. Depending on the operation system installed on
your laptop the message may differ from that shown below.

On the left side you can see the

screen after rebooting your
notebook.

For installing drivers please

insert the CD and select the
option button as shown at the
left side. Than press “continue”.

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PAL 300x - Operation Manual – Version 2.1.8

The drivers source should be

selected manually. Do the
corresponding settings and
continue.

Now select the CD-ROM drive.

Finish the installation.

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PAL 300x - Operation Manual – Version 2.1.8

Again an operating system message appears.

The remaining files must be installed. The approach is
Again an operating system
message appears. The
remaining files must be installed.
The approach is similar to
installing the driver. Select
automatic software installation
as shown on the left picture.

Finish the installation

A short message appears to

inform you the new hardware
device is ready for use.

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PAL 300x - Operation Manual – Version 2.1.8

Finally some settings concerning

the COM port must be changed.
Therefore open the device
manager and select the COM
port.

A contextual menu appears

when you right click on “High
the “advanced” button and another menu will open. Speed Communications Port
COM8”.

Click on the “advanced” button and

another menu will appear.

Change COM port number 1 to 9 and

confirm selection by pressing “OK” –
button. Close all other windows by
pressing “OK”. Now the computer is
ready for use with both the PAL 3001
and the CFM – MX crimp force monitor.

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PAL 300x - Operation Manual – Version 2.1.8

Should apear Hardware-Freeze,

you must open in the device manager
the settings of the High Speed
Communication Port (here COM4 /
COM5). In the picture of the left side,
you see the settings of the controller.
(The controller should have a value in
range of 100)

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PAL 300x - Operation Manual – Version 2.1.8
11 EU Declaration of Conformity

EU – Konformitätserklärung
EU Declaration of Conformity
Die Firma: C-tec Cable technologies GmbH & CoKG
The Company: Ilztalstraße 11
94513 Schönberg
Germany
Produktbezeichnung: Press Analyser
Product Press Analyser
Typenbezeichnung: PAL 3001
Type: PAL 3001
Das bezeichnete Produkt erfüllt die Bestimmungen der Richtlinie:
The above mentioned product complies with the regulations of the directives and amendments:
2006/42/EG Maschinenrichtlinie machine guideline
2006/95/EG Niederspannungsrichtlinie low voltage directive
2004/108/EG EMV-Richtlinie directive for electromagnetic compatibility
durch Einhaltung folgender Normen:
by adhering to the following standards:
DIN EN 12100-2 Teil 2/Part 1
Sicherheit von Maschinen, Technische Leitsätze
Safety of machinery, technical guidlines
DIN EN 14121-1 Teil 1/Part 1
Sicherheit von Maschinen – Risikobeurteilung Teil 1: Leitsätze
Safety of machinery – risk assessment Part 1: principles
DIN EN 55022 (Class A): 2008-05
Funkstöreigenschaften, Grenzwerte und Prüfverfahren
Radio disturbance characteristics, limits of measurement
DIN EN 55011:2007
Ind. wissenschaftl. und med. Hochfrequenzgeräte (ISM) Funkstörungen – Grenzwerte und
Messverfahren
Industrial, scientific and medical radio-frequency equipment. Electromagnetic disturbance characteristics. Limits and methods
of measurement
DIN EN 61000
1. 61000-4-2 Elektrische Entladung (ESD)
Electrostatic Discharge
2. 61000-4-3 Störfestigkeit gegen hochfrequente elektromagnetische Störfelder
Radio Frequency, Electromagnetic Field
3. 61000-4-4 Schnelle Transienten (Burst)
Fast Transients, AC Power Ports and Signal cables
4. 61000-4-5 Energiereiche Stoßspannungen
Electromagnetic compatibility (EMC). Testing and measurements techniques. Surge immunity test.
5. 61000-4-6 Störfestigkeit gegen leitungsgeführte Störgrößen induziert durch hochfrequente Felder
Immunity to conducted disturbances, induced by radio-frequency fields.
6. 61000-4-11 Störfestigkeit gegen Spannungseinbrüche, Kurzzeitunterbrechung und
Spannungsschwankungen
Voltage dips, short interruptions and voltage variation immunity test
DIN EN 60204-1 (VDE 0113-1): 2007-06
Sicherheit von Maschinen; Elektrische Ausrüstung von Maschinen, Teil 1: Allg. Anforderungen
Machine Guideline
Diese Erklärung wird verantwortlich abgegeben durch:
This declaration is submitted by:

(Ort, Datum) Lothar Schreiner

Place, Date Geschäftsführer General Manager

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