PAL 4000 – Operation Manual – Version 1.0.

PAL 4000
Electronic measurement device
for machine capability check
of crimping presses

Operation Manual
English
Version 1.0.0

Date: October 2016 Version: 1.0.0

Made by: L. Schreiner Checked by: M. Egginger
File: BA_PAL4000_EN_2016-V100
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PAL 4000 – Operation Manual – Version 1.0.0

Contents

1 Safety Regulations for Electrical Machines in Industrial Use ........................................................... 3

2 Function of the equipment ............................................................................................................... 4
3 Intended use.................................................................................................................................... 4
4 Technical specification .................................................................................................................... 4
5 Scope of delivery ............................................................................................................................. 5
6 Packing ........................................................................................................................................... 5
7 Transportation ................................................................................................................................. 5
8 Storing ............................................................................................................................................. 5
9 Set up .............................................................................................................................................. 5
10 Starting up ....................................................................................................................................... 6
10.1 Parts and tools ........................................................................................................................ 6
10.2 Preparations ........................................................................................................................... 7
11 Perform a press capability test ........................................................................................................ 8
11.1 Slow Motion Test .................................................................................................................... 8
11.2 Fine tuning of the press with 8 kN load ................................................................................. 11
11.3 Preparation of press analysis ............................................................................................... 13
11.4 Performing a press analysis ................................................................................................. 17
11.4.1 Trigger the press with the foot switch ........................................................................... 17
11.4.2 Trigger the press with the PAL relay box ..................................................................... 18
12 Transferring the test results to the PAL PC software ..................................................................... 20
13 Evaluation of the data on the PC ................................................................................................... 24
14 EU Declaration of conformity ......................................................................................................... 26

© 10/2016 C-tec Cable technologies GmbH & Co. KG, Ilztalstrasse 11, DE- 94513 Schönberg, Germany
Copies and prints only allowed under authorisation from C-tec. All rights reserved.
No liability for errors and omissions in contents and printing. This manual is not exhaustive.
Specifications are subject to change for product improvement without notice.
All used company labels are accepted.

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Please study this handbook carefully before initial use of the equipment. Keep this
handbook at the working place, where you can easily find it and hand it over with
the equipment to other persons.

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 parts and/or high voltage.
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

 Transportation, installation, commissioning, electrical connection, operation and maintenance

may only be carried out by authorized and qualified specialist staff.
 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.
 This instruction manual and especially the safety notes contained herein must be observed by
all the persons working with the system.

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.

Hotline

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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i Please be aware that the PressAnalyser PAL 4000 is a high precision gauge.
Handle it with care and provide a clean working environment.

2 Function of the equipment

The PressAnalyser PAL 4000 is an electronic measurement device to perform a machine capability
check of crimp presses with “mini applicator” standard. During the evaluation, the exact quality condition
of the crimping machine will be determined and reported by the calculation of a specific machine
capability index (CMK index). Built-in highly sensitive sensor technology is used to evaluate the
measurands length and force exactly in micrometer or newton. Even slightest deviations of the press
accuracy can be detected due to the precise sensors.
During the measurement, the PAL 4000 loads the crimping press with a constant counterforce of 8 kN.
The measuring values will be saved and entered in a graph where the values are statistically evaluated.
Additionally the PAL 4000 can be used as a height setting gauge. In contrast, conventional static dial
gauges the PAL 4000 allows to determine the difference between the ideal and the actual shut height
very comfortably in an automatic process.
Of course, before delivery the PAL 4000 itself is calibrated with high quality measuring gauges which
are released by a calibration laboratory accredited by the German Accreditation Body (DAkkS) to
examine crimp presses with “mini applicator” standard. The calibration should be repeated yearly.

3 Intended use
The PAL 4000 has been developed for examining crimp presses of “mini applicator type“. Usually, such
a press has a maximum press force of approx. 25 kN. The PAL 4000 can be loaded up to this force
level without any risk of damages. Exceptionally, also larger crimping presses can by tested with the
PAL 4000. But in this case special attention must be paid that the PAL won’t be damaged because of
the high load.
The requirements for temperature and humidity have to be carefully observed. Ignoring these rules can
cause accidents or damages. Other use as described in this manual is not allowed and can lead to the
loss of warranty claims and liability exclusion of the supplier. Any unauthorized modification of the
equipment carried out by user will invalidate the manufacturer’s liability to any resulting damage or injury
to personnel. This statement also applies for any changes or conversions of the device.

4 Technical specification
Type PAL 4000
Power supply 24 VDC
Max. charging current of battery 750 mA
Battery capacity after full load approx. 6 hours
Counterforce continuously variable from 1 – 20 kN
Resolution height sensor 0.5 µm
Resolution force sensor at 8 kN 2.5 N
Calibrated shut height 135.780 mm
Recommended room temperature 22°C +/- 5°
Protection class (against foreign substances) IP 44
Dimensions (W x D x H) 100 mm x 140 mm x 140 mm
Weight 4.6 kg

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5 Scope of delivery
Standard delivery must include:
 Case for transport and storing
 Main unit PressAnalyser PAL 4000
 USB 2.0 connector cable (USB-A to USB-B), 3m length
 Relay box for automatic press triggering
 Sharpening stone
 Power supply unit 24 VDC with adaptor kit, primary voltage: 100 – 240 VDC
 Serial interface cable RS 232
 CD with PAL PC software in the document compartment
 Calibration certificates in the document compartment
 Operation manual

6 Packing
The device is packed in a special transportation packing. Please re-use this package again or recycle it
according to your local rules.

7 Transportation
The transportation of the unit must be free of vibration and shock. The normal packaging is not
seaworthy and cannot be used for water carriage. The packing does not protect against wet conditions.
Tumbling of the unit during transportation is not allowed. Handle with care! Throwing or falling down of
the packed unit can cause damages or total demolition.

8 Storing
The PAL 4000 has to be stored in a dry and well-tempered room. The optimum storage temperature is
at 20°C. Too high humidity can cause corrosion on important precision parts.

9 Set up
The PressAnalyser PAL 4000 is intended for the check of crimping presses. For the test, the device
must be installed and firmly fixed in the press. Safety devices of the press must never be put out of
operation for the press inspection. The PressAnalyser has to be set up in a dry, dust free and well-
tempered room. It must be protected from improper environment conditions like high or low temperature,
direct sun light, vibrations and other mechanical influences, electromagnetic or magnetic fields, humidity
or dust.
If any defects, improper functions, damages or problems occur, which cannot be solved by the
instructions in this handbook, please set the device out of operation and contact C-tec for support.
DANGER TO LIFE: Never put safety devices of the crimping press out of operation. Please work only
with closed protection covers.

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10 Starting up

10.1 Parts, accessories and operating controls

Case for transport and storing

Document compartment

USB connection cable (USB-A / USB-

B)
PressAnalyser device PAL 4000

Bottom adapter plate for Toyo

standard (optional)
Ram adapter for Toyo standard
(optional)
Bottom adapter plate for Yazaki
standard (optional)
Ram adapter for Yazaki standard
(optional)
Serial interface cable
Power plug and charger
Screw set for adapters (optional)
Sharpening stone
Relay box for automatic press
triggering

Colour touch display

USB interface

Power on/off

Interface for relay box for press triggering

Port for power supply / battery charging

Serial interface for data exchange with crimp force

monitor

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10.2 Preparations

First clean the surface of the base plate with the

sharpening stone and possibly sand out imperfections.
Remove the grinding dust from the plate with a cloth.
Note: If the base plate is damaged too heavily, it must be
replaced.

Clean the surface of the pressure piece at the ram in the

same way by using the sharpening stone.

Note: If the pressure piece is damaged too heavily, it must

be replaced.

Now set up the PAL 4000 in the press and fix it there.

Attention: Both of the firm prisms

must equally enter the PAL body.

Fix the PressAnalyser with the

movable clamping claw
like a crimping tool.

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11 Perform a press capability test

11.1 Slow motion test

Press the Power ON/OFF key for at least 2 seconds. After

c. 2 s a short confirmation tone can be heard and the
button can be released.

After switching on, the PAL 4000 performs a self-diagnosis.

After a successful self-diagnosis the PAL 4000 switches to

the slow motion mode. This mode allows a rough pre-
selection of the press’ shut height. This helps to avoid
damages on the PAL or the press if the press is set to
deep.

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Turn the press ram by hand

through the bottom dead
center (BDC) and stop
shortly after the BDC. If the
press has a creep speed it
can be used to drive the
ram through the BDC.

BDC position (bottom dead center)

Stop the ram after the BDC position.

The PAL 4000 display shows the deviation of the BDC from
the optimal value of 135.780mm.
The yellow bar indicates the actual depth of the ram. The
yellow number on the right side shows the value of the
bottom dead center.
In this example the BDC is at 135.651 and thus 0.129mm
underneath the optimum value.

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Examples for extreme deviations in the shut height:

Attention: Press is set too deep (red bar). The BDC is at

135.482 mm and hence 0.3mm too deep.
The press must not be started!
Adjust the press ram approx. 0.3mm upwards.

Adjust the press ram

upwards and fix it with
the setscrew!

Press is set too high (yellow bar). The BDC is at 136.031

mm und thus 0.251 mm too high.

Adjust the press ram approx. 0.25 mm downwards.

Adjust the press ram

downwards and fix it
with the setscrew!

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Example for tolerable deviation of the shut height:

The bottom dead centre of the press is pre-set optimally.

Values between 135.600 and 135.960 are fine.

Attention: If the bar reaches the red area in the slow motion test, the press engine
shall not be started by any means.

11.2 Fine tuning of the press with 8 kN load

Touch the field =>8 kN on the touch screen. The servomotor

built in the device chooses the load for 8kN automatically.

The red dot on the force scale shows the current force
range of the servomotor.

If the button changes to 0 kN<=, the 8 kN position has been reached. In case of touching it again, the
0kN position (slow motion position) would be approached once again.

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Now the press can be started by engine power. As the PAL

now loads a counterforce of 8kN on the press, the press
“opens”. This means that the lower turning point (BDC)
which was set powerless previously, is shifted slightly
upwards. This characteristic can be found in all presses but
in different shapes.
Hence the lower turning
point has to be adjusted
downwards.

Adjust the BDC around

0.1 mm downwards.

Afterwards the press can be started again with engine

power. The lower turning point will be shown in the display.
This procedure has to be repeated till the BDC is set
around +/- 0.005 mm.

In this example the BDC is set 0.001mm above the

optimum.

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11.3 Preparation of press analysis

Press TEACH on the touch screen. The display switches to

the input window, in which you can enter the data of the
crimping press to be tested.

Input window for press data

Press the field New first.

The content of the field PressID now changes from default

to new.

Touch the
field new.

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Delete the word -new- by pressing the field Del.

Via the numeric keypad the press number (Press ID) can
be entered. It usually can be found on the type label.

Example:
Press number
is 34947

Enter the press number via the keypad. By touching the

field “abc” the keypad switches to the alphabet. The field
“Del” is used to delete wrong entries.

After entering the press number touch the field Ok.

Now hit again on OK to switch the data storage to the

actual press ID.

The press number appears in the field Press ID.

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Press OK to create a file for this crimping press on the

internal mass storage.

Now a menu appears which can be left by touching the field

EXIT.

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The PAL 4000 is now ready for running a press capability test.

Number of measurement readings

Target value for press shut height
Shut height tolerance band
Current force value
Tolerance band for the force analysis
Press number (ID)

Achieved CmK value for height

Achieved CmK value for force
Upper and lower limit for height
Upper and lower limit for force
Peak value line chart for height
Peak value line chart for force

Force setting
Pre-set starting cycles
Remaining calibration cycles
Battery power
Date

Start the crimping press to record the measuring values.

There are two possibilities to do this:

1. Trigger the press manually by the foot switch.

2. The PAL 4000 starts the press automatically. For this,

the relay box must be connected with the PAL 4000 and
also needs a connection to the signal of the foot switch.

Connection
with the relay
box.

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11.4 Performing a press analysis

11.4.1 Triggering the press with the foot switch

The most simple way is to start the crimping press with the
foot switch for all measuring cycles.
(C-tec recommendation: 150 cycles)

Example for a conducted test series

Number of measurement readings (150)

Last measurement value

Average over all readings
Largest single value
Smallest single value
Standard deviation
Cmk value of the test (machine capability index)

Column for height measurement

Column for force measurement

Peak value line for height

Peak value line for force

Press TEACH to save the single values in the internal bulk

memory (SD card).
The appearing window asks whether the
measurement should be saved or
discarded.
By touching Ok the measurement results
will be shifted to the internal mass
storage.

The PAL 4000 will shut down automatically after 5 minutes inactivity. In this case all measurement
values will be saved in the bulk storage before.

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11.4.2 Triggering the press with the PAL relay box

The press can be started by the PAL 4000 after the

connection between relay box and foot switch has been
established.

Press the field QUICK.

Press SETUP in the menu that now opens.

In the next menu the measuring rate for the press analysis
can be set.

Number of press triggers for a test

Length of starting signal

Length of signal pause

Countdown in seconds

The terms can be changed in wide ranges. Enter the

desired value via the numeric keypad.

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Press Start.

The countdown can be interrupted by touching ABORT.

After pressing Start, the selected countdown begins to run.

Meanwhile all safety devices can be closed properly. The
measurement starts after the countdown has finished.
The press will be started cyclically till the test series is
finished.

Example for a conducted test series.

(For explanation of the display please see 11.4.1)

Press TEACH to save the measurement values.

By touching Ok the measurement results

will be shifted to the internal mass
storage.

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12 Transferring the test results to the PAL PC software

Connect the
USB cable
with the PAL
4000 und a
USB port of
the PC.

Switch on the PAL 4000

Start the PAL PC software by double click on the icon on the desktop.

From version 2.1.16 on the software is compatible with PAL

4000 as well as PAL 3000.

The windows shows all presses which have already

been tested with PAL and of which the data has been
stored on the PC.

Click on the button “Import from Device“.

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The message: “Wait for connection...“ informs the user

that there isn’t a connection to PAL 4000 yet. If after
60 sec. there is still no connection, click on the field
„Find COM“.
This can be necessary for instance, when a USB port
of PC or laptop is used for the first time.

The PAL 4000 is connected now. This can be seen by

the charging status of the battery.

This message is shown if the internal time of the PAL

4000 differs from the PC time. Click OK, if you want to
adapt the PAL-time. If not, click Abbrechen.

The running arrows on the PAL display show that there is an active connection for
synchronization of the data with the PC.

On the right side of the screen you can see the yellow
highlighted projects (crimping presses) which are saved in
the PAL 4000 but haven’t been synchronized with the PC
software yet.
In our example there are two different presses.

With the first press a test series with 150 curves has been
performed.
For the second press we have 4 measurements with 150 resp.
106 curves each.

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With mouse click or mouse click + CTRL you can choose

one or more data sets for transmission.

In the example picture a press project with 3 data sets have

been chosen (highlighted in blue).

The data set for the crimping press with serial number 34947
inclusive the first three test series, has been selected.

Now click on the button <= (direction to PC).

The green colour on the left screen side indicates that the
PC memory is active.

Click on “Execute”.

This safety warning tells you that the data will be deleted in
the PAL storage after transmission to the PC.

You can confirm this message with OK and start the data
transfer.

The selected data is transferred now.

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Here the press ID and the data of the first

measurement are already transferred.
The second measurement is 50%
complete.

Here the data of the fourth measurement is just being transmitted.

All data have been transferred successfully.

Click on OK to exit.

Data synchronization has been completed.

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13 Evaluation of the data on the PC

To work with the data on the PC click on “Project” and choose

“Open” in the dropdown menu.

The transmitted press project appears in the tree structure.

By clicking on the + you can “fold down” the single test

series.

You can only select one test series by clicking on it. In the
example the last measurement has been chosen.

Press Ok to load the test series.

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The measurement data is now available on the PC monitor.

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14 EU Declaration of conformity

EG – Konformitätserklärung
EU Declaration of Conformity
-Original-

Die Firma: C-tec Cable technologies GmbH & Co.KG

The Company: Ilztalstrasse 11, 94513 Schönberg, Germany
Produktbezeichnung: Crimppressen-Analysegerät PAL 4000
Product: Crimp Press Analyzer PAL 4000
Typenbezeichnung: PAL 4000
Type: PAL 4000
Seriennummer: Herstellungsjahr:
Serial no.: Year of production:
Das bezeichnete Produkt erfüllt die Bestimmungen der Richtlinien:
The above mentioned product complies with the regulations of the directives and amendments:
2006/42/EG Maschinenrichtlinie machine directive
2011/65/EU RoHs Richtlinie RoHs directive
2014/30/EU EMV-Richtlinie directive for electromagnetic compatibility
durch Einhaltung folgender Normen:
by adhering to the following standards:
DIN EN 12100:2011-03
Sicherheit von Maschinen - Allgemeine Gestaltungsleitsätze - Risikobeurteilung und Risikominderung
Safety of machinery - General principles for design - Risk assessment and risk reduction
DIN EN 60204-1:2014-10
Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen - Teil 1: Allgemeine Anforderungen
Safety of machinery - Electrical equipment of machines - Part 1: General requirements
DIN EN 50581:2013-02
Technische Dokumentation zur Beurteilung von Elektro- und Elektronikgeräten hinsichtlich der
Beschränkung gefährlicher Stoffe (RoHs)
Technical documentation for the assessment of electrical and electronic products with respect to the restriction of
hazardous substances (RoHs)
DIN EN 61000-6-1:2007-10
Elektromagnetische Verträglichkeit (EMV) - Teil 6-1: Fachgrundnormen - Störfestigkeit für Wohnbereich,
Geschäfts- und Gewerbebereiche sowie Kleinbetriebe
Electromagnetic compatibility (EMC) - Part 6-1: Generic standards - Immunity for residential, commercial and light-
industrial environments
DIN EN 61000-6-3:2011-09
Elektromagnetische Verträglichkeit (EMV) - Teil 6-3: Fachgrundnormen - Störaussendung für
Wohnbereich, Geschäfts- und Gewerbebereiche sowie Kleinbetriebe
Electromagnetic compatibility (EMC) - Part 6-3: Generic standards - Emission standard for residential, commercial
and light-industrial environments
DIN EN ISO 13849-1:2016-06
Sicherheit von Maschinen - Sicherheitsbezogene Teile von Steuerungen - Teil 1: Allgemeine
Gestaltungsleitsätze
Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design

Diese Erklärung wird verantwortlich abgegeben durch:

This declaration is submitted by:

Ort, Datum Lothar Schreiner

Place, Date Geschäftsführer General Manager

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 Please consider your environmental responsibility before printing

this document.

Notes:

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