Automatic Cutting Machine: Powercut 3700

PowerCut 3700
Automatic Cutting Machine

Reference Manual
Software Version 1.0x |Edition 5.1 (05-2015)
| |PowerCut 3700
1 | 118
Address / distributors
Schleuniger AG Schleuniger, Inc.

Bierigutstrasse 9 87 Colin Drive
3608 Thun Manchester, NH 03103
Switzerland USA
P +41 (0)33 334 03 33 P +1 (603) 668 81 17
F +41 (0)33 334 03 34 F +1 (603) 668 81 19
info@schleuniger.ch sales@schleuniger.com
www.schleuniger.com www.schleuniger-na.com
Schleuniger AG Schleuniger Japan Co., Ltd.

Business Unit Solutions 4-5-8, Tokai, Ota-ku
Gewerbestrasse 14 Tokyo 143-0001
6314 Unteraegeri Japan
Switzerland P +81 (0)3 57 55 80 41
P +41 (0)41 754 53 53 F +81 (0)3 57 55 80 45
F +41 (0)41 754 53 50 sales@schleuniger.co.jp
solutions@schleuniger.ch www.schleuniger.co.jp
www.schleuniger.ch
Schleuniger GmbH Schleuniger Trading (Shanghai) Co., Ltd.

Raiffeisenstrasse 14 108, BH Center
42477 Radevormwald 7755 Zhongchun Rd
Germany Shanghai, 201101
P +49 (0)21 959 29-0 China
F +49 (0)21 959 29-105 P +86 (21) 62 52 66 77
info@schleuniger.de F +86 (21) 62 40 86 55
www.schleuniger.com sales@schleuniger.com.cn
www.schleuniger.cn
© 2015 Schleuniger
EN | ID-0000000142-006
Part #:
Order #:
2 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

Table of contents
TABLE OF CONTENTS
1 GENERAL 9
1.1 MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 MANUFACTURING DATE / PRODUCT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 INFORMATION ABOUT THE OPERATOR'S HANDBOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Contents of the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.2 Depository. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 GENERAL SYMBOLS AND LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.1 References and hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 WARRANTY STATEMENTS AND POLICIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 COPYRIGHT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8.1 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 SAFETY 13
2.1 WARNING NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 CAUTION PROPERTY DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 GENERAL SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 SOURCES OF DANGER / RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.5 INTENDED USAGE OF PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.1 Safety symbols used in manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.2 Safety symbols on the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 MODIFICATION AND RETROFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 PERSONNEL QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8.1 Personnel classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.9.1 Eye protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.2 Ear protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.3 Protective clothes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.4 Safety shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.5 Snood-type cap or safety cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.10 SAFETY INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 TRANSPORT / PACKAGING / STORAGE 17

3.1 TRANSPORT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 UNPACKING / LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3 PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700 3 | 118

Table of contents
3.3.1 The packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3.2 Handling packaging material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 INTERNAL TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 PRODUCT SPECIFICATIONS 19
4.1 DIMENSIONS / WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 REQUIREMENTS ON THE INSTALLATION LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 PRODUCT DESCRIPTION 23
5.1 CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 FRONT ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.2.1 Wire entry guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 Operator panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.3 Internal wire guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.4 Emergency stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.5 Safety cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.6 Setting knob for ejection chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 REAR / CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.1 Power connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.2 Main power switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.3 Fuse holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.4 Connector "Emergency stop link unit". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.5 Connector encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.6 Pedal connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.7 HS/PF (HotStamp/Prefeeder) interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.8 Postfeed interface (PPI, option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.9 RS 232 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.10 Connector „Second earth conductor“. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.11 Maintenance unit air pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 DANGEROUS ZONES ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.1 Safety marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 INSTALLATION / FIRST COMMISSIONING 29

6.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 SAFETY APPLIANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 POSITIONING / PUTTING INTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.1 Unpacking and setting up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.2 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.3 Setting the measuring unit and the menu language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 GENERAL HANDLING / OPERATION 35

7.1 GENERAL TOPICS FOR THE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 SWITCHING ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 SWITCH OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of contents
7.4 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.4.1 Loading wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.5 WORK TO BE DONE AFTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.5.1 General maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.5.2 Additional maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 OPERATION OF THE CONTROL SOFTWARE 39

8.1 OVERVIEW OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
8.1.1 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.1.2 Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2.1 Menu structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.2.2 Input area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.3 Entry fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3 MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.4 WIRE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.4.1 Wire data 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4.2 Wire data 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4.3 Wire data 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4.4 Wire marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4.5 Wire stacker (PPI, option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4.6 Cable coiler (PPI, option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5 FILE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5.1 New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5.2 Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.3 Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5.4 Save as. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.6 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.6.1 Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.6.2 User. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7.1 Info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7.2 Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7.3 Peripheral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.8 PASSWORD RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8.1 User level selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8.2 Change password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8.3 Password on/off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.8.4 Reset password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.8.5 Access rights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 OPERATION USING A MARKING DEVICE 59

9.1 INFORMATION FOR WIRE MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.2 INSTALLING THE WIRE MARKER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2.1 Determining the distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10 DIAGNOSTICS / TROUBLESHOOTING 61
10.1 GENERAL FAULT LOCALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Table of contents
10.1.2 Behavior in case of an error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

10.2 FAULT INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.3 DRAWINGS / CIRCUIT DIAGRAMS / FLOW CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.4 ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.5 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
10.6 ACTIONS AFTER SOLVING ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
11 MAINTENANCE / MAINTENANCE SCHEDULE 65

11.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.1.1 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.2 CUSTOMER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.2.1 Hotline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.2.2 Behavior in case of an error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3 CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3.1 Access rights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.4 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.4.2 Maintenance chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.5 CIRCUIT DIAGRAMS, DRAWINGS, SPARE PART LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.6 SPECIFICATION OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.7 GENERAL MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.7.1 General maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.7.2 Diagnostic cutter head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.8 SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.8.1 Setting the blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.8.2 Configuring the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11.8.3 Setting back to factory default. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.9 MAINTENANCE / REPAIR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.9.1 General / safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.9.2 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.9.3 Replacing blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.9.4 Replacing transport belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.9.5 Exchanging mains fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12 SPARE PARTS / EXPLODED VIEW DRAWINGS 85
13 DECOMMISSIONING / DISPOSAL 87
13.1 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
13.2 DISASSEMBLY / RECYCLING / DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14 APPENDIX 89
14.1 SOFTWARE UPGRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
14.1.1 Installing Iguana . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
14.1.2 Downloading upgrade file. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
14.1.3 Upgrade procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
14.2 CONNECTOR HS / PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Table of contents
14.2.1 For use with a PreFeeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

14.2.2 For use with a HotStamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
14.3 PRE-/POSTFEED INTERFACE (PPI, OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
14.3.1 POSTFEED interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
14.4 BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14.5 LUBRICATING GREASE MICROLUBE GBU-Y 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INDEX 115

Table of contents

1. General
GENERAL
Thank you for your trust in the Schleuniger technique! You have acquired a high performance Schleuniger
product, designed and manufactured in our factory to your needs. Read through this manual with due
care and attention. It contains important tips and safety instructions, which allow precise and reliable pro-
duction.
We have taken every possible measures to ensure the accuracy and completeness of this documentation.
Since errors can be avoided despite the diligence never fully, we are always grateful for any advice and
suggestions.
1.1 MANUFACTURER
In this Manual, Schleuniger AG Thun, Switzerland is referred to as manufacturer and abbreviated with
„Schleuniger“.
Schleuniger AG Phone: +41 (0)33 334 03 33

Bierigutstrasse 9 Fax: +41 (0)33 334 03 34
3608 Thun Email: info@schleuniger.ch
Switzerland Web: www.schleuniger.com
1.2 MANUFACTURING DATE / PRODUCT TYPE

See “EG-Declaration of Conformity (Register 2)“ of the ring binder.
1.3 INFORMATION ABOUT THE OPERATOR'S HANDBOOK

■ The Operator's Handbook is part of the product and contains all the relevant information necessary to
operate the product efficiently and safely as intended.
■ The mentioned safety notes and directions and as for the application field valid local accident preven-
tion regulations and general safety regulations must be complied.
■ If the product changes hands, the Operator's Handbook must be supplied to the new owner.
■ Make sure to update any relevant safety changes and corrections to the Operator's Handbook which
are available. Ask your local Schleuniger distributor for updates.
1.3.1 Contents of the manual

General
Each person using the product must be properly trained and have read and understood the operator
manual. This is also imperative, even when the respective person has operated such a product or similar
previously and where they have been trained by the manufacturer.
The operator manual is no longer valid, if any of its contents (except a Quick Start Card, where available)
are removed or is changed on the data storage medium.
As operator manual we declare:
■ In printed form the entire content of the folder according to the contents table.
■ In electronic form, this „Reference Manual“, and the document „Parts Catalog“.
Construction
We are trying to make the operation of our products as easy as possible. To achieve this we have devel-
oped a concept for the Operator's Handbook.
The Operator's Handbook consists of at least three parts:

1. General
Quick Start Card (optional)

The Quick Start Card is available as a quick reference to take out of the ring binder. It is meant for the user
(operator), which is operating the product daily. See chapter "2.8.1 Personnel classification (Page 15)".
Reference Manual
A detailed description for the product and all options with full explanation of all functions available and
the maintenance. The Reference Manual is meant for the beginner as well as for the experienced user
(qualified personnel) as a learning- and reference guide. See chapter "2.8.1 Personnel classification
(Page 15)".
Parts catalog
A manual with the most important components of the product including the available options and the
wear parts. This part of the Operator's Handbook is intended mainly for the technical specialist. See chap-
ter "2.8.1 Personnel classification (Page 15)".
1.3.2 Depository
The Operator's Handbook must be available to the operating personnel at all times. Keep the Operator's
Handbook in such a way that it will not become damaged, so that the contents will remain clearly legible
beyond the expected lifespan of the product.
1.3.3 Responsibilities
■ This Operator's Handbook must be kept near the product. It must be available to the operating per-
sonnel at all time.
■ Always follow the instructions in this Operator's Handbook fully and without restraint.
1.4 GENERAL SYMBOLS AND LEGEND
1.4.1 References and hints

The listed pictograms have the following meaning in the Operator's Handbook:
Tip: Info:
Application note and other useful infor- Information which helps to operate the
mation which improves the intended uti- product efficiently and error-free.
lization of the product.
Magnifier: Menu level:
Overview diagram, introduction chapter. 1-2-3 Sub-screen with indication of the screen
level (viewed from main menu).
Procedure: Figure reference:
3
Important activity direction, program- Referencing of text to picture elements in a
ming example. previous figure.
Topic: Disposal:
Important safety relevant reference. Waste that must be recycled and not be
disposed of with household waste.
Tab. 1: General symbols used in this instructions

1. General
1.4.2 Legend
Key, button, pictogram Commands and operating areas on the screen are in the text shown in bold,
squared brackets and capital letters [KEY].
Screen title/menu Screen titles and menu names are represented in the text in "inverted com-
mas".
Electric signal name Signal names are marked in capital letters and in "INVERTED COMMAS".
Cross referencing Cross referencing is indicated in the text in color and italics, e. g. see chapter
"1.4.2 Legend (Page 11)".
Activity direction Activity direction (installation procedure, programming example and others)
requests the user of the product to take an action. The activity direction is
marked with a digit and an arrow „1»“.
Consequence of an Descriptions and affected actions in activity directions are marked with the
activity direction prefix „➥“.
Measure Measures in the manuals are given in millimeters.
1.5 DECLARATION OF CONFORMITY

See document “EG-Declaration of Conformity (Register 2)“ of the ring binder.
1.6 LIMITATION OF LIABILITY

The content of these operating instructions was put together taking into consideration the current stand-
ards and guidelines according to the state of the technology and our many years of experience.
The manufacturer disclaims any liability for damages and accidents as a result of:
■ Disregard of the instructions
■ Disregard of warning notices
■ Non-intended usage
1.7 WARRANTY STATEMENTS AND POLICIES

See Schleuniger document „General Conditions of Sale and Delivery”.
1.8 COPYRIGHT PROTECTION

Keep this operator manual confidentially. It is intended for the exclusive use of persons operating the
product. Without written agreement, this manual shall not be made available to third parties.
The content of the operator manual in the form of text, illustrations, drawings, circuit diagrams or other
presentation, is protected by copyright law of the manufacturer.
1.8.1 Trademarks
Cayman™ and Iguana™ are trademarks of Schleuniger.
Windows® (XP, Vista, 7, 8 or CE) are registered trademarks of Microsoft Corporation in USA and other
countries.
All other brands or product names are trademarks or registered trademarks of their owners.
Registered trademarks are not specially marked in these instructions. However, this does not mean that
they can be used freely.

1. General
For further information, see chapter "14 Appendix (Page 89)".
1.9 SPARE PARTS

Always order original spare parts from your local Schleuniger distributor.
Any modifications in design or function of the spare parts, in terms of ongoing product improvement, are
subject to change without prior notification.
CAUTION
Use of unverified spare parts!
Unverified or defective spare parts may lead to damage, malfunction or com-
plete failure of the product and may affect safety of operator personnel.
Exclusive use of original Schleuniger spare parts is imperative.

2. Safety
SAFETY
2.1 WARNING NOTICES

The warning notices in the entire Operator's Handbook are marked with the following symbols. They are
headed by a safety alert symbol and the warning word which represents the degree of endangerment.
To avoid any injuries or material damage it is essential that you read and fully understand these symbols.
DANGER
Warning notice „Danger”
This panel indicates a hazardous situation, which if not avoided, will result in
death or serious injury.
WARNING
Warning notice „Warning”
This panel indicates a hazardous situation, which if not avoided, could result in
death or serious injury.
CAUTION
Warning notice „Caution
This panel indicates a hazardous situation, which if not avoided, may result in
minor or moderate injury.
2.2 CAUTION PROPERTY DAMAGE

NOTICE
"Property damage"
This panel indicates a hazardous situation, which if not avoided, can result in
damage to property.
2.3 GENERAL SAFETY NOTES

■ The product must only be operated when in good working order and condition. It must be checked
for intactness prior to the start of operation.
■ Never operate the product in an explosive or flammable environment.
■ Only operate the product in a dry, dust-free environment.
■ Before performing any maintenance or repair work, unplug the machine from the mains and/or from
the air pressure supply.
■ Never operate the product without connecting the earth conductor.
■ Only use original Schleuniger equipment, especially interface connection cables (electromagnetic
compatibility).
■ The product must always be operated through the Schleuniger emergency stop link unit, if it works
together with peripheral devices in a production line. Only then can a safe interruption of the com-
plete production line during an emergency be guaranteed.
■ Any lubricating grease supplied with the machine, may only be used according to the instructions
given in this manual.

2. Safety
2.4 SOURCES OF DANGER / RISKS

With the use of technical products are dangers associated.
Dangers that could not be eliminated by design measures and also not by protection devices are residual
risks. The safety instructions in this Operator's Handbook refer to the known residual risks. Should be
shown additional operational risks, the operator is obliged to inform Schleuniger immediately.
However, the following risks remain:
■ Inadequate maintenance can cause injury to the operator personnel and malfunction on the product.
■ When working with a production line (PreFeeder, CableCoiler, WireStacker), in the wire/cable area by
catching body parts and clothing. Always close off these areas!
■ On the wire/cable exit, wires/cables are ejected with high speed. There is a danger of stab wound and
concussion injury. Always close off this area!
■ Risk of wire/cable blocking. Tensile forces can move to overturn machine, peripheral or bobbin and
injure the operator personnel.
■ The product may come down the working table due to vibration and injure the operator personnel.
■ A free standing panel may fall due to vibration and injure the operator.
■ Tripping, falling, slipping due to connection cables, wire residue and air hoses lying around.
■ Risk of increased noise levels while working with multiple machines in the room. Arrange for noise
control measures!
■ Wires/cables may contain talc which can strain the work environment during wire/cable processing.
■ By working with insufficient illumination in the workplace can cause injury.
2.5 INTENDED USAGE OF PRODUCT
WARNING
Only use the product according to the intended usage!
Any use of the product, which contradicts the intended use, is regarded as non-intended use. Schleunig-
er is not liable for any damages resulting from a non-intended use.
WARNING
Caution, risk of injury, property damage!
It is designed and manufactured exclusively for the following intended application:
The PowerCut 3700 must be used only for cutting of cables, wires and tubes within the given range
according to the technical specifications.
Disregarding may lead to injury of the operator personnel and to property damage.
2.6 SAFETY SYMBOLS
2.6.1 Safety symbols used in manual

In this manual, safety symbols are used which alert the user to potential hazards. They will be described
here in detail.

2. Safety
General Danger! Notes and instructions with this safety symbol should be followed
strictly. Disregarding may lead to injury and damage to the
machine.
Electric current! There is a danger of electric shock by contact with parts inside the
machine and on the mains socket. Therefore before opening the
machine always switch off the main switch and unplug it from the
mains. Touching electric components can cause injury to the oper-
ator personnel.
Electrostatic sensi- Electronic parts react sensitive to static charge. Specially marked
tive components! components and packaging must only be handled by trained per-
sonnel after a potential equalization and with special equipment.
2.6.2 Safety symbols on the product

On the product, safety symbols are attached which alert the user to potential hazards. An overview where
this stickers are attached to, can be found in chapter "5 Product description (Page 23)".
2.7 MODIFICATION AND RETROFITTING

To avoid any dangerous situations and for an optimal performance, it is not allowed to make any modifi-
cations to, or retrofitting of the product, without explicit written permission of the manufacturer or the
local Schleuniger distributor. Standard options and accessories supplied by Schleuniger are excepted.
2.8 PERSONNEL QUALIFICATION

The individual tasks may only be performed by persons listed in the respective chapter.
The product is intended to be operated by personnel older than 14 years. It is strictly forbidden to grant
access to younger person.
CAUTION
Inadequate qualification!
Improper usage of the product may lead to injury for the operator.
There are danger zones where special caution is advised. The product should be
operated only from the group of persons listed in the corresponding chapter.
2.8.1 Personnel classification

The following classifications in these instructions are specified for the individual activities.
Operating company
As a parent entity that is responsible for the proper use of the product and for the training and the com-
mitment of authorized persons. It defines the mandatory competencies for its operation and authority of
the authorized personnel.
Technical specialists
Due to product-specific training and mechanical and electrical skill and experience, are qualified to per-
form maintenance and repair work on the product.

2. Safety
Qualified personnel
Due to product-specific training, technical skill and work experience are qualified to install the software,
to put the product into operation and to instruct the operating personnel.
Operating personnel
Is a person who has been trained and authorized by the management to operate the product safely
according to the instructions. They have the ability to identify all sorts of danger and to avoid it. This
includes an adequate knowledge of accident prevention and first aid procedures.
Third party
Externally called in personnel of the operating company, service technicians and staff from Schleuniger.
2.9 PERSONAL PROTECTIVE EQUIPMENT

While working on the product, always wear protective equipment according to the local regulations to
minimize the risk of injury.
■ Always wear protective equipment necessary for the work being carried out.
■ Observe the safety markings for the protective equipment in the working area.
2.9.1 Eye protection

To protect the eyes from small particles produced during wire/cable stripping and cutting.
2.9.2 Ear protection

During the operation of several machines, the noise level may increase. Constant noise can have a nega-
tive impact for the operator. In this case wear ear protection.
2.9.3 Protective clothes

Wear tight-fitting clothes with low tensile strength and no protruding parts. Protects from getting caught
up in moving machine parts.
2.9.4 Safety shoes

To protect from heavy, falling objects or reels.
2.9.5 Snood-type cap or safety cover

To protect long hair from getting caught up in moving machine parts.
2.10 SAFETY INSTALLATIONS

The built in safety interlocks on the machine (safety, protection, monitoring) must not be removed, by-
passed or changed. The safety circuits should be checked periodically. Defective safety equipments must
be fixed immediately before work may be continued.
■ Never operate the machine without the safety hood.
■ Never operate the machine if the safety cover is open.
■ The emergency stop buttons must always be accessible.
■ Do not remove any safety barriers.
■ Do not break in the emergency stop link between the machine and the peripheral devices.

3. Transport / packaging / storage
TRANSPORT / PACKAGING / STORAGE

During unpacking, transportation or storage of the product always observe the following instructions.
They contain important information to avoid injury to the operator and property damage. Take into con-
sideration the weight of the machine during transportation and loading. See chapter "4.1 Dimensions /
weight (Page 19)".
Personnel qualification
The instructions in this chapter must be carried out by qualified personnel!
NOTICE
Improper transportation!
Improper transportation may lead to serious property damage to the product
and the craft.
■ Handle with care and always observe the symbols and hints on the packag-
ing and the product when unloading and placing on site location.
■ Only use the intended transportation accessories from Schleuniger.
3.1 TRANSPORT INSPECTION

Check the goods immediately after receiving for completeness and loss during shipment.
For loss on the packaging during shipment, proceed as follows:
■ Do not accept the delivery or only with exceptions.
■ Declare loss of shipment.
■ Immediately report damages on the product.
3.2 UNPACKING / LOADING

Take out the machine carefully from the package. Remove any transport lockers, binders and foam and
check for free moving of cylinders and drives (if available, read the packing instruction).
NOTICE
Observe packaging direction!
Disregarding while unpacking the product may lead to serious property damage.
If provided, observe the packaging notice on the outside of the product and
observe the unpacking sequence.
NOTICE
Transportation locks!
If the transportation locks are not removed before operating the product may be
damaged.
Before use of the product, remove, if present, any marked transport fixations
(store for later use).

3. Transport / packaging / storage
3.3 PACKAGING
3.3.1 The packaging

Store the packaging for later use on a weatherproof location.
3.3.2 Handling packaging material

Recycle the unneeded packaging.
See chapter "13 Decommissioning / disposal (Page 87)".
3.4 INTERNAL TRANSPORTATION

As applicable, transport the product in the original packaging.
Always carry around the product on the handles or by the help of a lifting device. During transportation in
a sloping terrain, the product must be secured properly so that it cannot go away or slip uncontrollably.
For lifting wherever applicable use a mechanical appliance. Always carry around the product as of a cer-
tain weight with several people according with the regulations.
CAUTION
Load displacement / uneven weight balance!
During transportation in a craft, the product may slip off, thrown out of balance
and cause serious property damage. Even the craft may start skidding, which
could result in an accident with incalculable consequences.
■ Always secure the product in the craft to prevent from slipping off.
■ Observe position of center of gravity, see chapter "4.1 Dimensions / weight
(Page 19)".
3.5 STORAGE
Store the product under the following conditions:
■ Not outdoor
■ Observe temperature conditions
■ Observe climatically conditions
See also chapter "4.2 Technical specifications (Page 19)".

4. Product specifications
PRODUCT SPECIFICATIONS
This chapter among others gives an overview of the important technical specifications of the product.
The technical data correspond to the theoretical values and achievable under normal conditions. Any
modifications in design or function, in terms of ongoing product improvement, are subject to change
without prior notification.
4.1 DIMENSIONS / WEIGHT
A B
Fig. 1: Dimensions
Description Value Unit

Weight (net) 65 kg
Measures Length (A) 640 mm
Width (B) 440 mm
Height (C) 530 mm
4.2 TECHNICAL SPECIFICATIONS

Limit values Aperture height (tubes up to 20 mm) 25 mm
Aperture width 82 mm
Conductor cross section (dependent on wires 70 (AWG 2/0) mm2
and blades)
Feed speed 4.5 m/s
Pulling force 230, peak 660 N
Length 400 M
Power Length 100 mm 7600 Pcs./h
Length 2000 mm 3750


Length resolution 0.1 <40m mm
1.0 <40m
Mains connection Power connection 230/240 V
Line frequency 50/60 Hz
Power consumption 120 VA
Compressed air min. 6 bar
max. 10
Air consumption @ 4000 pcs./h, 1 bar 1600 Liters
Noise emission Emission sound pressure level <85 dB(A)
Environment Temperature range 5-40 °C
Relative humidity, maximum 90 @ 20 °C %
50 @ 40 °C
Storage and transport temperature -25 to +55 °C
Interfaces Prefeeders and wire marker devices, RS 232
Optional: Pre-/Postfeed interface for synchron-
ized peripheral devices (PPI, option)
Options Pedal
Air jet unit
Carbide blades
Tube cutting unit
Adapter kit for CC 1300 / CC 1400 / CC 4000,
WS 3150
Synchronized pre-/postfeed interface
Emergency stop link unit
4.3 REQUIREMENTS ON THE INSTALLATION LOCATION

Place on a solid, level work floor. The machine is designed for handling on table height.
We recommend to use the optional Schleuniger system rack.

4.4 RATING PLATE

In order to ensure efficient support for our part, we ask the customer on any requests to always communi-
cate the exact content on the rating plate.
The rating plate is situated on the side of the machine and contains the following information:
Schleuniger AG
Bierigutstrasse 9 CH-3608 Thun / Switzerland
Model: PowerCut 3700

Serial No: XXXX-2013
Power rating: 230/240 VAC T5.0 A
50/60 Hz 1000 VA
Made in Switzerland
1 4 2 5 6 3
1 Machine type 4 Serial number

2 Permissible mains voltage 5 Mains frequency
3 Internal fuse protection 6 Power consumption


5. Product description
PRODUCT DESCRIPTION
This chapter gives a description of product specifications, information on the limits of the product and
points on the scope of delivery. The individual parts are shown and described by photographs. Further
provides the product description information about the functioning and the operation modes.
5.1 CONCEPT
The PowerCut 3700 is the ideal cutting machine for round and flat material with larger cross sections. The
machine feeds the wires with high accuracy and speed. The powerful pneumatic cutter head achieves a
clean right-angled cut and may be used for a wide range of applications.
The PowerCut 3700 may be used as a stand-alone machine as well as a host in a fully automated wire pro-
cessing line. The PowerCut 3700 is equipped with different interfaces for peripheral devices.
5.2 FRONT ELEMENTS

4
3
6
2
1 8
Fig. 2: Main view front
1 Wire entry 5 Emergency stop button

2 Wire entry guide 6 Safety door
3 Operator panel 7 Access protector wire exit
4 Internal wire guides 8 Setting knob for ejection chute
5.2.1 Wire entry guide

The guides on the wire entry are used amongst others for flat ribbon cables to make sure that the cable is
guided correctly during the processing and not to drift off.

5.2.2 Operator panel

The operating software of the PowerCut 3700 is controlled via the operator panel.
5.2.3 Internal wire guides

The internal wire guide is used for the wire guiding after the transport belts. The wire is guided exactly to
the ejection chute.
5.2.4 Emergency stop button

The emergency stop button cuts any power to the PowerCut 3700 immediately. For this, push the red but-
ton fully down until it snaps in.
To disengage the emergency stop button, turn it.
5.2.5 Safety cover

The safety door ensures a safe and secure operation of the PowerCut 3700. As soon as the door is opened,
the drives are switched off via the safety switch and also the air pressure supply. Jammed wires and wire
residue on the belts can be easily removed therewith.
5.2.6 Setting knob for ejection chute

With this lever the ejection chute is aligned in height to the post processing device (cable coiler, wire
stacker).

5.3 REAR / CONNECTORS
5 6 7
8
4
9
3 10
11
12
1
Fig. 3: Overview rear / connectors
1 Maintenance unit air pressure 7 Pedal connector

2 Power connection 8 HotStamp/PreFeeder interface (HS/PF)
3 Main power switch 9 Not implemented.
4 Fuse holder 10 Pre-/postfeed interface (PPI, option)
5 Connector „Emergency stop link unit“ 11 RS232 interface
6 Connector encoder 12 Connector "Second earth conductor"
5.3.1 Power connection
NOTICE
Line voltage!
The PowerCut 3700 must only be operated with the line voltages rated on the
rating plate, see chapter "4.4 Rating plate (Page 21)".
5.3.2 Main power switch

The PowerCut 3700 is turned on and off on the main switch.

5.3.3 Fuse holder

The fuse holder contains the two pluggable mains fuses. For the fuse change, see chapter "11.9.5 Exchang-
ing mains fuses (Page 85)".
5.3.4 Connector "Emergency stop link unit"

An optional external Schleuniger emergency stop link unit can be connected. Therewith, a network of
automated cut and strip and also peripheral devices can be stopped immediately in an emergency case.
If you intend to use an emergency stop link unit of a third party vendor, check for compatibility with your
local Schleuniger distributor first.
5.3.5 Connector encoder

To this connector an optional encoder for the exact measuring of the wire length can be connected.
5.3.6 Pedal connector

The cutting procedure may be started with the pedal.
5.3.7 HS/PF (HotStamp/Prefeeder) interface

To this connector a Hot stamp or a PreFeeder can be connected.
For use with a HotStamp

The interface is optimized for the Schleuniger peripheral devices listed below:
■ HotStamp 4140
■ HotStamp 4500
The PowerCut 3700 produces a marking pulse and interrupts the device during the marking time.
For a detailed description of this interface, see chapter "14.2.2 For use with a HotStamp (Page 92)".
For use with a PreFeeder

The interface is optimized for the in chapter "14.2.1 For use with a PreFeeder (Page 91)" listed Schleuniger
peripheral devices.
The Prefeed operation may be monitored by the PowerCut 3700, see also chapter "8.6.1 Devices (Page 50)".
5.3.8 Postfeed interface (PPI, option)

This optional interface includes the following ports for synchronized peripheral devices:
■ CableCoiler 1300
■ WireStacker 3150
■ Coilers and stackers from third party vendors (with device specific adaptation)
See also chapter "14.3 Pre-/postfeed interface (PPI, option) (Page 93)".
5.3.9 RS 232 interface

For the connection of a PC. Therewith wire programs can be saved and reloaded to/from an external
memory in future. This connector is also used for software upgrades.

5.3.10 Connector „Second earth conductor“

On the rear, right of the power connector, the machine has an additional earth wire connection.
Connect the provided earth wire according to the country specific regulations to this connector and on
the other side hook it up to the environment installation of the building by an electrician.
WARNING
Raised leakage current!
Due to the fact that the leakage current of the frequency converter used in the
product, is greater than 10 mA the following precaution according to the valid
standard EN 60204-1 must compulsory be followed. Operating the machine
without this second earth conductor is due to safety related reasons not permit-
ted and may lead to serious injury or death.
5.3.11 Maintenance unit air pressure

The machine must be connected to an air pressure supply for the correct functioning of the cutter unit.
The air pressure is supplied via the maintenance unit on the back of the machine.
5.4 DANGEROUS ZONES ON THE MACHINE
5.4.1 Safety marking

Safety markings affixed to the product, advert to possible danger situations and must be strictly
observed. The safety markings must not be removed. Damaged or illegible labels must be replaced
immediately.
For further information, see chapter "5 Product description (Page 23)".

Unplug the machine from the mains- and the air pressure sup-
ply!
There is a danger of electric shock by contact with parts inside the
machine and on the mains socket. Touching electric components
can cause injury to the operator personnel.
Unintentional operation of pressurized components or uninten-
tionally escaping compressed air can cause injury.
Therefore always before opening the machine:
■ Turn off the main switch, block against switching on again and
disconnect the machine from the mains (for hard wired
machines, the main switch serves as a mains disconnecter
unit).
■ Unplug the machine from the air pressure supply.
Connect second earth conductor!
This machine has a high leakage current. Disregarding this proce-
dure may lead to an electric shock. Before connecting to the mains
supply the earth connection must be made. Connect the provided
earth wire according to the country specific regulations to this
earth connection and on the other side hook it up to the environ-
ment installation of the building by an electrician.
General danger There is a general danger of injury from moving parts in the pro-
zone! cessing area. When reaching into the feeding area during produc-
tion, the user can infringe on the fingers.
Escaping pro- On the wire exit wires are fed out at high speed of the machine.
cessed wires! Escaping wires can injure eyes, face and other parts of the body. Do
not stay in this area if the machine is running.

6. Installation / first commissioning
INSTALLATION / FIRST COMMISSIONING

This chapter describes the working steps for the mounting and commissioning of the machine.
6.1 SAFETY INSTRUCTIONS

The installation and commissioning instructions for the product, have to be followed. The following
instructions must be followed step by step to avoid property damage on the product and to reduce the
risk of injury to the personnel to an absolute minimum.
NOTICE
Sequence of instructions!
Improper usage may lead to injury.
The following instructions must be carried out in the listed sequence.
Safety relevant points

The following security relevant points have to be mentioned specially:
■ This is a free-standing product.
■ The machine must only be operated in a dust free and dry area.
■ The electric connection must be carried out by a technical specialist and according to the local instal-
lation regulations, see also chapter "4.2 Technical specifications (Page 19)".
Safety appliances / danger areas

■ For localizing the safety elements, see chapter "5.4 Dangerous zones on the machine (Page 27)".
■ For localizing the danger areas around and in the machine, see chapter "5.4.1 Safety marking
(Page 27)".
6.2 SAFETY APPLIANCES

See chapter "5 Product description (Page 23)".
See chapter "5.4 Dangerous zones on the machine (Page 27)".

6.3 POSITIONING / PUTTING INTO OPERATION
6.3.1 Unpacking and setting up
WARNING
Risk of injury through high tension!
The transport unit of the PowerCut 3700 has a high tension. If the supply of the
cutting material is not fully warranted during operation, the machine can be
pulled of the table during production.
■ Compulsory screw together the PowerCut 3700 with the Schleuniger system
rack.
■ Compulsory fix the work bench down to the floor with the optional fixation
kit.
1.▹ Unpack the machine.

2.▹ Remove all transportation locks (foam material pieces).
3.▹ Place the machine on the Schleuniger system rack / work bench.
Placing the machine on the Schleuniger system rack

See also mounting procedure System rack, Doc.# 419877.
1.▹ Slide in the screws (1)

with the sliding blocks
into the universal table 118 mm
top.
2
2.▹ Mount the positioner 2
rails (2). 2
1
3.▹ Attach the mounting

bracket (3) with both
screws (4) to the
PowerCut 3700.

4.▹ Place the

PowerCut 3700 in the
centering rings (5).
5.▹ Slide the screws (1)
into the mounting
bracket and attach it.

Mounting the machine on the rack

1.▹ Open the safety door.
2.▹ Remove the rear cover.
3.▹ Mount the
1
PowerCut 3700 with
the screws (1) to the
work bench (through
holes in the base sup-
port).
4.▹ Fixate the work bench Rear Front
on the floor (2).
5.▹ Mount the rear cover.

6.▹ Close the safety door.
Attachment points
R = rack system 2 x M6x50
W = work bench 2 x Ø11

6.3.2 Commissioning
WARNING
Raised leakage current!
The PowerCut 3700 is equipped with an additional grounding wire connection
on the rear. Connect the provided earth wire according to the country specific
regulations to this connector and on the other side hook it up to the environ-
ment installation of the building by an electrician. Operating the machine with-
out this additional grounding is due to safety related reasons not permitted.
1.▹ Mount the grounding wire (1) to the

PowerCut 3700 and on the environment instal-
lation of the building.
Caution: While mounting the cable lug, put on the

parts in the following order: Serrated washer->
cable lug-> washer -> nut.
2.▹ Plug in the power cord (2).

3.▹ Connect the compressed air to the mainte-
nance unit (3). 2
4.▹ The desired air pressure is adjusted on the dial
4
(4). (min. 6 bar, max. 10 bar).
Caution: Use only dry, clean, oil free air pres-
sure.
5.▹ Connect the optional pedal.

6.▹ Possibly connect the PC to the RS 232 connector.
7.▹ Possibly connect to the optional emergency stop link unit.
6.3.3 Setting the measuring unit and the menu language

1.▹ Turn the main switch on the PowerCut 3700 on. Possibly disengage the emergency stop button.
2.▹ [MENU] --> [3] - Configuration --> [2] - User.
3.▹ Select the menu language / measuring unit with [@], [ENTER].
4.▹ Back to the main menu with 2× [MENU].


7. General handling / operation
GENERAL HANDLING / OPERATION

The operation of the PowerCut 3700 is described in this chapter in detail.
7.1 GENERAL TOPICS FOR THE OPERATION
The instructions in this chapter must be carried out by operator personnel!
Before the daily operation a visible check on the machine must be carried out.
■ Guides and blades must be held clean from wire residue and other particles.
■ Wire/cable guides and the area of the blades must be cleaned with a brush and/or possibly with a
vacuum cleaner, see also "11.7.1 General maintenance (Page 67)"
See also chapter "5 Product description (Page 23)".

See also chapter "5.4 Dangerous zones on the machine (Page 27)".
CAUTION
Raised noise exposure!
Depending upon the nature of the certain cutting material and the force applied
to the machine, the noise level can be a strain to the operator. In this case wear
ear protection.
7.2 SWITCHING ON
1.▹ Disengage the emergency stop button on the PowerCut 3700 and on the emergency stop link unit.
2.▹ Turn on the main switch on the rear of the machine, see "5.3 Rear / connectors (Page 25)"
3.▹ Wait until the machine has been initialized.
7.3 SWITCH OFF

1.▹ Turn off the main switch on the PowerCut 3700.
2.▹ Disengage the emergency stop button.

7.4 SETUP
7.4.1 Loading wire

1.▹ Switch on the machine.
2.▹ Open the guide on the wire entrance and the
internal guides fully.
3.▹ Insert the wire in the direction of the arrow
below the wire end switch.
4.▹ Adjust the position and gap of the internal

guides according to the wire in process and
fixate.
5.▹ If available, select an appropriate wire pro-

gram, see chapter "8.5.2 Load (Page 49)".
Notice: If the machine is switched to gap mode

„manual“, make sure that the gap setting equals
the wire diameter, see chapter "8.4.3.2 Gap
(Page 46)".
6.▹ [CLOSE]
➥The drive closes to the point where the wire
sensor detects the wire or to the pre-set value.
7.▹ Feed the wire [FEED].
8.▹ Cut the wire [CUT].
9.▹ Adjust the position of the internal guides
according to the wire in process.
10.▹ [SINGLE]
➥Produce a test wire and check the wire
length.
Instead of using [CLOSE], [FEED] and [CUT] the wire may also be loaded automatically with [LOAD].
Thereby the drive closes to the point where the wire sensor detects the wire or to thepre-set value. Then
the wire is fed and cut.

7.5 WORK TO BE DONE AFTER OPERATION
7.5.1 General maintenance

■ After 1 day: Clean the processing area.
■ After 1 week: Clean the housing and the processing area.
7.5.2 Additional maintenance work

For further information, see chapter "11 Maintenance / maintenance schedule (Page 65)".


8. Operation of the control software
OPERATION OF THE CONTROL SOFTWARE
8.1 OVERVIEW OPERATOR PANEL

1 2
3 4 5
Fig. 4: Operator panel with keyboard and display
1 Display 4 Navigation keys

2 Production keys 5 Entry keys / numeric keypad
3 Function keys
8.1.1 Display
Header line
Main area
Header line
The following display is shown:
■ Product name, title of the corresponding menu.
■ Name of the loaded wire or "?" (wire not saved) "8.5 File menu (Page 48)"

■ An "x" on the right corner indicates, that additional screens for the same level are available.
Main area
Display of menus, parameter entries, messages.
8.1.2 Keyboard
Navigation keys
Navigation keys: The arrow keys are used for the navigation within the lists, such as in the
"File" screen ("8.5.2.1 Procedure (Page 49)") or at the input fields (cursor).
Function keys
Menu: This key guides level by level back to the main menu. In dialog boxes this key has the
function [OK].
Define selection: Allows for an additional selection within the dialog boxes (instead of [OK]
and [CANCEL]). Serves as an additional special function key.
Next: This key guides to the next screen on the same level. In dialog boxes this key has the
function [CANCEL].
Production keys
Open/close: Opens/closes the transport belts.
Feed: Feeds the wire as long as this key is pressed.
Cut: Performs a cutting procedure.
Load /unload: The wire is automatically loaded/unloaded.
Start production: Starts the production of the programmed wire.
Single wire: Produces a single wire with the programmed, current settings.
Stop: Interrupts the production.

Entry keys
0...9 Numeric keypad: With the numeric keypad, characters and numbers can be entered in the
entry fields.
Cancel: Aborts the entry.
Back: Confirms an entry and returns to the previous input field.
Delete: Deletes the last entered character.
Toggle key: Toggles between different states. In addition the leading sign with the plus/
minus key and upper/lower case with characters can be switched.
Decimal point
Enter: Confirms an entry and jumps to the next input field.
8.2 GENERAL
Below the display there are three blue keys, see chap-
ter "8.1 Overview operator panel (Page 39)". For selecting
the desired screen use [MENU] and [NEXT]. [MENU]
returns to the screen level above. The key [NEXT]
switches between several screens, marked with a (x) on
the right of the header line, between the same level. In
certain screens the function key [+] is used for the exe-
cution of special functions.

8.2.1 Menu structure

The software of the PowerCut 3700 is structured in a main menu with 5 sub menus.

8.2.2 Input area

There are two types of input areas, which make up two different screen types:
■ Menu screen
■ Entry screen
In menu screens the indicated functions or sub menus

can be selected with [1]...[9] according to the shown
menu.
In input screens use the fields for the entry of values

and settings. Navigation from field to field can be car-
ried out with the [ENTER]/[FORWARDS] or [BACK-
WARDS] key. The entered value is immediately saved
as soon as the field was exit. If the value of an input
field was changed unintentionally the former value can
be reset with [ESC] as long as that field was not exit.
8.2.3 Entry fields

There are three types of input fields:
■ Toggle fields
■ Numeric fields
■ Text fields
Toggle fields can be switched with @.

Enter the values for the numeric fields with [0]... [9] / [.].
Delete single characters with [DEL], switch the leading
sign with [+/-].
Enter the values for the text fields with the [0]...[9] (0-9,
abc - wxyz, special characters, space) / [.]keys. Delete
single characters with [DEL]. To toggle between upper
and lower case can be done with [+/-].

8.3 MAIN MENU

If the [MENU] key is pressed after switching on the
machine, the main menu is shown on the display.
8.4 WIRE SCREENS
8.4.1 Wire data 1

After switching on the PowerCut 3700 the user auto-
1
matically accesses the screen „Wire“.
The number of wires to produce (Total), the batch (@
batch / @ batch left) with batch size and the wire
length is determined here.
Press [+], [OK] to delete the production status.
Press the key [×] to enter the following screens.
8.4.2 Wire data 2

Here the speed and the ramp (acceleration) with which
1-X
the wire shall be transported is determined.
Speed
These settings change the feed speed of the transport; whereas 0 is the smallest and 9 the largest selecta-
ble value.
Table of speeds
Step 0 1 2 3 4 5 6 7 8 9
m/s 0.25 0.5 1.0 1.25 1.5 2.0 2.5 3.2 4.0 4.5
Ramp (acceleration)
These settings change the ramp (acceleration) of the transport, whereas 0 is the smallest and 9 the largest
selectable value.
There are two operating modes (toggle with [@]):
Table of the ramps, fast

Step 0 1 2 3 4 5 6 7 8 9
ms 1000 900 800 700 500 325 250 150 75 25

Ramp time in ms corresponds to a maximal speed of 4.5 m/s.
Table of the ramps, slow

Step 0 1 2 3 4 5 6 7 8 9
ms 10000 9000 8000 7000 5000 4000 3000 2000 1000 500
The following criteria will help to select a meaningful ramp behavior:

Ramp behavior fast
■ high dynamic behavior of the peripheral devices
■ low to middle wire weight
■ non-slippery surface
■ low to middle accuracy of length
Ramp behavior slow

■ low dynamic behavior of the peripheral devices
■ high wire weight
■ slippery surface
■ precise accuracy in length
%-correction
Due to the nature of the wire and the type of wire
feeding length deviations may occur while processing.
With the correction function, the deviation can be
compensated.
With the %-correction the lengths are linearly correc-
ted by the calculated factor. The correction factor is
calculated with the following formula:
given value
New correction factor = old correction factor x
measured value
The %-correction can be calculated by the PowerCut 3700.

Enter the measured wire length (actual length) and
press [+]. The calculated value is adopted to the %-cor-
rection field, the measured wire length is reset to 0 and
marked with an "x" at the length line on the screen
„Wire data 1“.

8.4.3 Wire data 3

Contact pressure
Here the pressure is defined, the wire is pressed by the
1-X-X
transport unit during the transport.
Gap
There are two methods to determine the gap of the transport unit (toggle with [@]):
Automatic
The PowerCut 3700 closes the transport unit, detects the wire diameter and sets the gap automatically.
Manual
Enter the desired gap manually in „Gap Aperture“.
For the processing of flexible cutting material (e. g. tubes) or materials with dimensions smaller than
4 mm, we recommend to set the gap opening manually.
Gap = Ø - 1 mm.
Cut pullback
This function enables the pull back of the wire after the cut cycle before the blades open.
Cut pullback:
Activate or deactivate the function „Cut pullback“.
Length pullback:
Sets the value how much the wire gets retracted after the cut.
The retract function slows down the production.
8.4.4 Wire marking

In this screen the wire marker data is determined. This
screen is only shown if the wire marker device under
„Configuration - Devices“ is switched on.
See also chapter "8.6.1.2 Configuration HotStamp
(Page 51)" and "9.2 Installing the wire marker unit
(Page 59)".
Right / left
Optionally we can choose whether to
place markings on the left, the right
or on both sides of the wire. Therefore
the distance from the left/right wire
end has to be entered.

Continuous
With this setting the markings are
placed along the whole wire in peri-
odical distance.
We can enter either the left and/or

the right position, although a contin-
uous marking is possible also if no val-
ue for „Left“ and „Right“ is entered.
Left end space

To ensure that a continuous marking
is not placed to close together or
even overlays, the minimal spacing to
the left marking can be entered here.
Minimal spacing Enlarge text spacing
Enter enough text spacing as the text length is not taken into account with the wire marker.
NOTICE
Incorrect behavior software!
By using a HotStamp device with the PowerCut 3700 under certain circumstances
an incorrect behavior can occur.
Condition where the error occurs (example):
■ Wire length 400 mm
■ Marking position from right 100 mm
■ Distance HotStamp to PowerCut 3700 = 500 mm
E. g. if „Wire length + marking position = HotStamp distance“, then the error

occurs. In case of the error the HotStamp carries out only the first marking and
no other.
The error can be bypassed if one of the three values is changed.
8.4.5 Wire stacker (PPI, option)

In this screen the wire stacker data is determined. This
screen is only shown if the wire stacker device under
See also chapter "8.6.1.3 Configuration WS 3150 (PPI,
option) (Page 52)".
Ejection time [ms]

The PowerCut 3700 activates the output „Postfeed“ during the entered time. The ejection time depends
on the duration of the stacking.

Wait (ms)
The PowerCut 3700 waits for the entered time, until the WS 500/1000 was moving to its home position.
Subsequently the production continuous.
8.4.6 Cable coiler (PPI, option)

In this screen the cable coiler data is determined. This
screen is only shown if the cable coiler device under
See also chapter "8.6.1.4 Configuration CC 1300 / CC
1400 / CC 4000 (PPI, option) (Page 52)".
Binding position
The PowerCut 3700 interrupts the production after the programmed "Binding position". This is shown in
the „Info-Box 240“. On this position now the coiled wires can be bound or marked. Press the pedal to
continue the production or [STOP]to interrupt.
■ The binding position must be longer then the distance between cutting axis and clamping pin.
■ The binding position must be shorter then the wire length minus the distance cutting axis to clamp-
ing pin.
8.5 FILE MENU

From the main menu the screen „File“ can be reached
2
with the key [2]. At the screen „File“ you load, save or
delete the wire data. The memory handles up to 100
wires.
8.5.1 New
With the menu entry "1." „New“ the values of the
2-1
present wire are reset to the default values. The
present wire always is the one indicated on the screen
„Wire“.

8.5.2 Load
Load a saved wire. The user is asked whether to over-
2-2
write the present wire, indicated on the screen (Warn-
ing 111). This warning only appears if the present wire
is different from the saved one. Once the message is
confirmed with [OK] the screen „Load“ pops up.
Procedure
In the list in the upper area of the screen, the name of
the wire can be selected with [UP] / [DOWN]. On the
text input field below the name can be entered direct-
ly. The list selection thereby jumps to the next entry.
■ With [OK] the actual wire is loaded and the soft-
ware changes directly to the screen "Wire".
■ With the key [+], the currently selected wire on the
list is deleted, see chapter "8.5.2.3 Deleting a wire
(Page 49)".
■ The screen can be left with [×] without loading a
wire. Display of compatibility
Display of compatibility
Symbol Meaning
Saved and current wire data are identically.
Saved and current wire data are identically. Total is different.
Saved and current wire data are different.
Deleting a wire
At the screen „Load“ and „Save as“, wires can be
deleted by pressing the [+] key. The warning "999" is
shown.
The entry is confirmed with:
■ [OK] The wire is deleted and with further deleting
procedures the warning is issued again.
■ [+] The wire is deleted, while the warning does not
appear again with further deleting procedures
until this screen is exit again.
■ [×] The wire is not deleted.
The selection [+] „Delete without warning“ is useful if several wires are intended to be deleted.

8.5.3 Save
With the menu „Save“ the loaded and edited wire can
2-3
be saved. If a new, unsaved wire has to be saved by
means of „Save“ the user is automatically guided to the
„Save as“ screen.
8.5.4 Save as
This screen operates like the screen „Load“ with the
2-4
following exception:
With [OK] the actual wire is saved and the screen "File"
is displayed again.
Procedure
In the list in the upper area of the screen, the name of
the wire can be selected with [UP] / [DOWN]. On the
text input field below the name can be entered directly
or an existing name renamed. The list selection thereby jumps to the next entry.
■ With [OK] the present wire is saved under a new name.
■ With the key [+] delete, the currently selected wire on the list is deleted, see chapter "8.5.2.3 Deleting a
wire (Page 49)".
■ The screen can be left with [×] without loading a wire.
8.6 CONFIGURATION
From the main menu the screen „Configuration“ can
3
be reached with the key [3]. In the „Configura-
tion“ screen all necessary machine settings can be car-
ried out with the following items:
■ [1] Devices
■ [2] User
8.6.1 Devices
In this screen the following devices can be activated /
3-1
deactivated and the "Combi" function is switched on/
off.
Feeders:
■ PreFeeder
Marking devices:
■ HotStamp
Post processing devices:

■ WireStacker
■ CableCoiler
Additional screens are activated accordingly.
Combi on / no Combi
With the operation of a wire marker device the wire feeding on the PowerCut 3700 is interrupted through
the Combi input until the marking procedure is completed, see chapter "9 Operation using a marking
device (Page 59)".
During automatic processing without a marking device, the feeding on the PowerCut 3700 is stopped as
long as the switch between pin 4-5 remains closed. The processing continues as soon as this switch is
opened again. See also chapter "14.2.2 For use with a HotStamp (Page 92)".
Configuration HotStamp
In this screen all parameters for the wire marker device
3-1-X
are determined. See also chapter "9.2 Installing the wire
marker unit (Page 59)".
Distance
In order to correctly position the marking the distance between the two devices must be entered into the
PowerCut 3700. See also chapter "9 Operation using a marking device (Page 59)".
Pulse duration [ms]

During the pulse duration the output of the connec-
tion on the marking device is activated. The marking
time is set on the marking device. Via the input of this
connection the PowerCut 3700 is stopped during the
marking process.
Timeout usage
This parameter switches the "Timeout-function" on/off.

Timeout
The PowerCut 3700 monitors, if a marking device is
operating or not after startup. If the marking device
does not confirm the printing for any case, an error
message will appear. The duration until an error mes-
sage appears is called „Timeout“ and can be set up.
Configuration WS 3150 (PPI, option)

In this screen all parameters for the wire stacker device
3-1-X-X
are determined. Here also stackers from third party
vendors (with device specific adaptation) can be con-
figured.
Distance
In order to correctly position the marking the distance between the two devices must be entered into the
PowerCut 3700. For this measure the distance from the cutting axis to the adapter with a measuring tape.
Configuration CC 1300 / CC 1400 / CC 4000 (PPI, option)

In this screen all parameters for the cable coiler device
3-1-X-X
are determined. Here also coilers from third party ven-
dors (with device specific adaptation) can be config-
ured.
Distance
In order to take over the wire on the right position, the Cutter
distance between the two devices must be entered
into the PowerCut 3700.
For this measure the distance (1) from the cutting axis
to the coiling position with a measuring tape.

8.6.2 User
In this screen the language and the measuring unit is
3-2
set. For this see chapter "6.3.3 Setting the measuring
unit and the menu language (Page 33)".
Available language packets:
Standard East
English English
Deutsch Deutsch
Italiano Cesky
Français Polski
Español Magyar
Slovensky Româna
In addition the hints are set to:

■ No hints
■ Important hints
■ All hints
8.7 DIAGNOSTICS
From the main menu the screen „Diagnosis“ can be
4
reached with the key [4]. At the „Diagnosis“ screen all
necessary diagnostics are made:
■ [1] Info
■ [2] Machine
■ [3] Peripheral
8.7.1 Info
This screen contains the following information to the
4-1
PowerCut 3700:
■ Current software version
■ The produced total wires
■ Serial number of the motor power amp
■ Software version of the implemented optional PPI
(pre-/postfeed interface)
8.7.2 Machine
In the „Diagnosis Machine“ screen the functioning of
4-2
the following components is tested:
■ Screen
■ Keyboard
■ Sensors
■ Cutter head (see chapter "11.9 Maintenance / repair
work (Page 74)")

Screen
The menu item „Screen“ inverts the screen. This way the display can be checked for pixel errors.
4-2-1
Keyboard
Here the functioning of the keyboard is tes-
4-2-2
ted. Therefore press any key that is shown
under "Info 999 key: ...“ is displayed (in the
example the key [RUN]).
Press [MENU] to terminate the keyboard test.
Sensors
Here the functioning of the sensors is tested.
4-2-3 ■ 0: indicates a non active sensor
■ 1: indicates an active sensor
Wire end switch: Insert a long, thin pin into the wire
entry and move around. Lifting up or releasing the wire
end switch triggers a modification of the display
between "0" and "1".
Gap Home: Close the transport unit with [ARROW UP] or [ARROW DOWN]. The sensor is activated if the
transport unit is opened fully.
8.7.3 Peripheral
Here the functioning of the following peripheral devi-
4-3
ces is tested:
■ Prefeeder
■ Pedal
■ Marking device
■ Pre-/postfeed interface (PPI, option)
Prefeeder
Here the functioning of a connected prefeeder is tes-
4-3-1
ted. For this follow the instructions on the screen.

Pedal
Here the functioning of a connected pedal is tested.
4-3-2
Activating or deactivating the pedal triggers a modifi-
cation of the "Info 999 actuate pedal":
■ 0: indicates a non active pedal (not actuated, as
shown in the example).
■ 1: indicates an active pedal (actuated).
Wire marker
Here the functioning of a connected marking device is
4-3-3
tested. For this follow the instructions on the screen.
PPI (option)
WARNING
Danger if operated by unqualified personnel!
The diagnostic on the PPI must only be carried out by Schleuniger personnel or a distributor.
Here the functioning of an optional connected PPI is

4-3-4
tested.
Preparation:
1.▹ Turn the machine off

2.▹ Install the interface kit
3.▹ Connect the interface tester
4.▹ Switch on the machine
Diagnostics with built in interface:

Start the test with the [+] key. The following criteria indicate an error free functioning of the interfaces.
The test takes about 6 seconds:
■ The single red LED on the interface test print glows.
■ The pair of LED on "Postfeed" flashes alternately orange and green = OK.
■ The relays on the test prints click hearable.
Error codes:
Error code of the interface Meaning of the message on the display

Postfeed Inkjet
FF FF No interface built in
FF 0F Interface built in, no test adapters connected
00 - Interface built in correctly, all in- and outputs OK

Error codes Postfeed Outputs defective Inputs defective

00 all OK all OK
01 PNP: ROUT0 PNP: RIN0, RIN1
02 PNP: ROUT0 NPN: RDETECT
04 PNP: ROUT1 PNP: RIN1
08 PNP: ROUT2 PNP: RIN2, RIN3
10 PNP: ROUT3 PNP: RIN3
20 NPN: ROUT1 NPN: RIN2
40 NPN: ROUT2 NPN: RIN2, RIN3
80 NPN: ROUT3 NPN: RIN3
FF all defective all defective
?? Random error code possible due to hexadecimal addition
8.8 PASSWORD RESTRICTION

From the main menu the screen „Password“ can be
5
reached with the key [5].
Based on the menu „Password” the individual menus
can be reached with [1]...[4], back to the main menu
with [MENU].
In the menu „Password“ the four user levels "Standard /
Supervisor / Service / Produce" can be activated/deac-
tivated and the access rights are determined/blocked.
8.8.1 User level selection

In this mode the desired user level can be activated. If
5-1
this screen is left with [×] and the password is switched
on, the user automatically resides in the password lev-
el "Produce".
8.8.2 Change password

This screen is only shown with activated user level
"Standard" or „Supervisor“.
Enter a new password and repeat the entry to confirm
the password.

In order to save the password, exit the screen with

5-2
[OK].
8.8.3 Password on/off

This menu item is only shown with activated user level „Supervisor“.
5-3
8.8.4 Reset password

This menu item is only shown with activated user level
5-4
„Service“. This menu item resets all passwords to the
factory setting.
8.8.5 Access rights

Level Restriction
Service All rights
Supervisor (pass- All rights except: Configuration / change machine
word 123)
Standard (password All rights except:
12) - Configuration / change user
- Configuration / change machine
- Change diagnostics
Produce (no pass- All rights except:
word) - Change configuration (only turning devices on and off is allowed)
- Execute diagnostics
- Delete wires in the file menu
WARNING
■ Only users with password level "Supervisor" can activate the password pro-
tection.
■ Once the password is deactivated, all entries can be changed.
■ The standard passwords must be changed and put aside. If a password gets
lost, the passwords can be reset. This is reserved for the user level "Service".


9. Operation using a marking device
OPERATION USING A MARKING DEVICE
9.1 INFORMATION FOR WIRE MARKING

■ Only program the marking when the wires are being cut accordingly or temporarily enter 0 (sample
wire) in the „Marking (marker)“ menu. This way any wire loss can be held on a minimum.
■ The PowerCut 3700 automatically calculates the wire loss (waste piece) that takes place during the
start of the processing. The distance between the marking device and the PowerCut 3700 has no influ-
ence on the resulting production quantity.
■ To obtain only one print enter the position „Right" in the screen "Wire marking".
■ To obtain a print in the middle of the wire, enter half the wire length in the „Right" position.
■ If the entire typeface has shifted, the distance between marking device and the PowerCut 3700 has to
be measured and reprogrammed.
9.2 INSTALLING THE WIRE MARKER UNIT

1.▹ Install a HotStamp left next to the
1
PowerCut 3700 (see also the oper-
ating manual HotStamp). The pro-
cessing axis of both devices must Cutter
be aligned in the X- and Y-axis.
2.▹ Plug the connecting cable into
the interface „HS/PF“.
If a Schleuniger HotStamp device
is used the connection cable is
enclosed.
3.▹ The distance (1) from the cutting
axis (blades) of the PowerCut 3700
to the right side of the printing wheel edge should not exceed 1 m.
4.▹ Fasten the device securely. The distance should not be changed during operation (applies specially
to the PowerCut 3700, if applicable use the original Schleuniger machine rack).
5.▹ In order to correctly position the marking, the distance (1) between the PowerCut 3700 and the mark-
er device must be entered into the PowerCut 3700.
9.2.1 Determining the distance

Determine the distance (1) as follows:
1.▹ Measure the distance (mm) with a measuring tape from the right printing wheel edge to the cutting
axis.
2.▹ Switch on both devices
3.▹ Enter the distance in the menu "Configuration - HotStamp", see chapter "8.6.1.2.1 Distance (Page 51)".
4.▹ Choose the desired pulse duration (in ms).
➥During the pulse duration, the output of the „HS/PF“ interface is activated.
5.▹ Leave the screen.
6.▹ Program a wire with a marking.
Determine the distance conveniently:
1.▹ Load a wire on both devices (make sure that the wire was cut).
2.▹ Carry out a test marking.
3.▹ Press [FEED] until the marking of the wire is visible on the PowerCut 3700 exit.

9. Operation using a marking device
4.▹ Press [CUT], to eject the marked wire.

5.▹ Measure the distance from wire beginning to the right edge of the marking.
6.▹ Enter the distance in the menu "Configuration - HotStamp".

10. Diagnostics / troubleshooting
DIAGNOSTICS / TROUBLESHOOTING
Errors and others can occur if excessive pollution affects the guidance and blade functions.
Regular inspection and maintenance reduces the risk of unexpected faults and increases the reliability
and life cycle of the machine. Maintenance work must be accomplished according to the instructions and
the time intervals listed. See chapter "11.4 Maintenance schedule (Page 66)".
10.1 GENERAL FAULT LOCALIZATION
10.1.1 Safety instructions
General
Safety appliances must not be deactivated or removed inadvertently.
If a fault condition occurs always check first if the line power is switched on and then perform a diagnostic
check.
10.1.2 Behavior in case of an error

We advise the customer in case of a serious fault, to contact the local Schleuniger distributor, see "Page 2“.
10.2 FAULT INDICATORS

Errors recognized by the software or the internal electronics show up on the display.
Fig. 5: Fault indicators

10.3 DRAWINGS / CIRCUIT DIAGRAMS / FLOW CHARTS

Drawings, circuit diagrams and flow charts may be helpful during trouble shooting. See chapter
"14 Appendix (Page 89)".
10.4 ERROR MESSAGES

Error Text Description/action
1 Safe mode! No production possi- Initializing could not be performed.
ble.
2 - -
3 HotStamp timeout. HotStamp device is not responding. Message from
production.
4 No feedback from HotStamp. HotStamp device is not responding. Message from
diagnosis.
5 Blade blocked! Production can- The cutting procedure could not be completed
celed. fully. Blocked by too thick wires.
6 No wire! Wire end switch detects no wire.
7 No more memory. Delete first. The wire memory already contains 100 wires. You
have to delete existing wires to be able to save new
ones.
8 Invalid name, empty or used: \\ / : File name invalid. Characters like / : * ? \" < > | are
* ? \" < > | not allowed.
9 File not found. A file which is missing was entered.
10 No prefeeder connected. Appears on diagnose if a prefeeder is being tested
although none is connected.
11 No pedal detected. Appears on diagnostic if a pedal is being tested but
none is connected.
12 RAM corrupted. The internal memory changed unintended. This
indicates an error with the FRAM. Hardware
exchange is indispensable.
13 Actual value not in range. %-correction calculation. If the value is beyond the
permitted range, the calculation is not carried out.
14 Enter correct password! The password for the selected user level is wrong.
15 Password confirmation wrong! While changing the password the confirmation was
entered incorrectly.
16 Illegal operation for current user The selected function is not allowed with the
level. present user level.
17 Communication error to PPI. The Pre-/postfeed interface is not implemented.
18 Prefeeder blocked! The prefeeder is not switched on or the wire entry
area is blocked.
19 No wires found. No more memory.
20 Servo AI. Alarm from transport motor.
21 Servo not ready. Fault in the motor power amp. Switch off and then
on again the machine.

Error Text Description/action

22 Communication error to servo. Communication to the servo not possible. Servo or
other hardware defective.
23 Servo. No response from PED. Position end PED not responding. Error on servo or
other hardware.
24 No response from cutter head. Blades not in end position. Check air pressure con-
nection and settings.
25 Loading canceled. Failed to load the wire.
26 - -
27 Gap could not initialize. The wire is to thin, or the gap sensor is defective.
28 No servo found. Servo does not respond on initialization. Servo not
configured correctly or cable not connected prop-
erly.
29 No response from servo. No response from from transport motor.
30 max. contact pressure reached. Gap is set to small. (if gap is set to manually).
31 Wire to short for coiler. The wire length must be at least the distance from
the cutting axis of the PowerCut 3700 to the clamp-
ing pins of the coiler.
10.5 WARNINGS
Warning Text Explanation
000 Data changed. You overwrite existing wire data.
102 Production finished. If the production is completed (Total = Produce),
then this message appears with a new start with
[RUN].
103 Reset production state? The user explicitly requires to reset the production
state.
104 All data will be lost! Really want to There is an option to delete the complete memory.
delete whole memory? This warning reminds you of it.
105 No more wire! The wire end switch is activated during production.
Wire still can be completed.
106 File available! Overwrite? An already existing file name was entered.
107 Delete, warn again. This warning is only triggered in combination. See
warning 999.
108 Delete without warning message. This warning is only triggered in combination. See
warning 999.
109 Do not delete. This warning is only triggered in combination. See
warning 999.
110 Reset wire data! Appears if „File“ --> „New“ was selected.
111 Loading overwrites the current A wire is being loaded, although the present wire
wire! was not saved. Changes are lost.

Warning Text Explanation

112 Unknown data format! This message can appear after an upgrade if the file
format does not match anymore. The user may
return to an older version or confirm deleting all
data with [MENU].
113 Prefeeder blocked! The prefeeder is not switched on or the wire entry
area is blocked.
114 Back to factory defaults! This resets all data to the factory setting. All wire
programs are deleted.
999 Delete, warn again. Appears with deletion of wire data.
Delete without warning message.
Do not delete.
10.6 ACTIONS AFTER SOLVING ERRORS

To check the correct functioning of the machine before the series production, a functional check has to
be performed.

11. Maintenance / maintenance schedule
MAINTENANCE / MAINTENANCE SCHEDULE

Periodic inspection and maintenance eliminates the feasibility of unexpected errors and improves the
reliability.
This chapter contains the description of general maintenance work to be done on the product, which can
be carried out by qualified and trained personnel on site.
All maintenance and cleaning work apply to one-shift-operation. For work in multiple shift operation, the
interval times are shorten accordingly.
11.1 SAFETY INSTRUCTIONS
11.1.1 Personal protective equipment

See chapter "2.9 Personal protective equipment (Page 16)".
11.2 CUSTOMER SERVICE
11.2.1 Hotline
We advise the customer in case of technical problems with the machine, to contact the local distributor
first, see „www.schleuniger.com”.
11.2.2 Behavior in case of an error

If problems occur, which cannot be solved by the help of this manual, the Schleuniger distributor or the
technical staff of Schleuniger is ready to assist you. In such situations it is essential to provide a precise
description of the matter.
■ Exact machine name
■ Serial number of product
■ Software version (incl. language packages).
■ Exact description of the error (error no. shown on the screen, if available)
■ Under what circumstances has the error shown up
■ What peripheral devices where connected to the machine when the error occurred
■ Wire type to be produced at the time the error occurred
Soft- and hardware versions and other information can be read in the diagnostics.
11.3 CLASSIFICATION
11.3.1 Access rights

See chapter "2.8.1 Personnel classification (Page 15)".

11.4 MAINTENANCE SCHEDULE
11.4.1 General
The development and construction of the machine is focused on a minimal maintenance effort. Mainte-
nance work is mainly constricted on cleaning and lubricating certain components and removing dust and
debris. The listed maintenance intervals however can vary depending on the type of material produced
and the environmental conditions.
It is important that the system is checked periodically to find out about the grade of dirt and abrasion.
11.4.2 Maintenance chart

Maintenance work must be accomplished according to the instructions and the time intervals listed. Gen-
erally proceed according to the following chart:
Component Activity Interval Reference Time con-

(Page) sumed
(Min.)
Housing clean weekly 67 2
Processing area clean weekly 67 2
Blade clean/check weekly 67 2
Drives clean/check weekly 67 2
11.5 CIRCUIT DIAGRAMS, DRAWINGS, SPARE PART LISTS

See chapter "14.4 Block diagram (Page 102)".
Document „Parts Catalog“.
11.6 SPECIFICATION OF SPARE PARTS

See document „Parts Catalog“.
11.7 GENERAL MAINTENANCE WORK

The cleaning interval depends on the type of material processed and the intensity of the application. The
blade area, the wire/cable guides should be held free of waste material in order to ensure precise strip-
ping results. Dirt and talcum residues may affect the functioning of the machine. The machine has to be
checked and necessarily be cleaned.
CAUTION
Electric shock!
There is a risk of an electric shock in the area of the power connector and the
fuses during cleaning when touching electric components, which can lead to
injury.
■ Do not touch electric components.
■ Before cleaning always switch off and unplug the product from the mains.

NOTICE
Avoid using aggressive solvents!
Aggressive solvents may damage the safety covers and the surface.
■ For cleaning, never use aggressive solvents
■ Clean the exterior casing and the plastic parts with a soft cloth and a usual
commercial cleaning agent.
11.7.1 General maintenance
The instructions in this chapter must be carried out by operator personnel!
Cleaning the housing

1.▹ Switch off and unplug the machine from the
mains supply.
2.▹ Clean the cover with a soft cloth and a com-
mercially obtainable cleaning agent.
Cleaning the interior

1.▹ Open the safety door.
2.▹ Clean the processing area with a brush and
possibly with a vacuum cleaner.
3.▹ Clean the cutter head and the belts with a
brush and possibly with a vacuum cleaner.
4.▹ Check the blades for worn-out or damages.
➥Replace outworn or damaged blades.
5.▹ Check the transport belts for worn-out or dam-
ages.
➥Transport belts with little adhesion, worn-
out or damaged must be replaced.
7.▹ Connect the machine to the mains and switch
it on.

11.7.2 Diagnostic cutter head
NOTICE
Caution, property damage!
The menu "Diagnostics cutter head" is only accessible with password level "Serv-
ice", see chapter "8.8 Password restriction (Page 56)".
Contact your local Schleuniger representative!
The cutter movement of the PowerCut 3700 is monitored electronically. In case of an error, the message
„Blade blocked“ is displayed:
Cause of fault Actions to be taken

Cutter head not in home position - Air pressure not connected
- Adjust the pressure for min. 6 bar
Cutting operation not finished - Cutting material to thick
- Adjust the pressure for min. 6 bar
Sensor „Home position“ defective or misaligned Check sensor
Sensor „Cutting position“ defective or misaligned Check sensor
In the menu „Diagnostics cutter head“ the function of the sensor is checked on the cutter cylinder:
1.▹ Based on the main menu go to the menu "Password" with the key [5].
2.▹ Select [1] „Level“.
3.▹ With [@] select the password level "Service".
4.▹ [ENTER]
5.▹ Enter password.
6.▹ [ENTER]
7.▹ 2 x [MENU]
8.▹ Based on the main screen, press the following keys to enter the screen „Diagnostics cutter head“: [4]
„Diagnostics“ -> [2] „Machine“ -> [4] „Cutter head“.
9.▹ Home position:
Sensor, upper blade Sensor active, 0 Sensor inac-
tive
10.▹ Cutting position:
Sensor, lower blade, 1 Sensor active, 0 Sensor inac-
tive

11.8 SETTINGS
The machine was calibrated in the factory to your needs. After a blade replacement, the replacement of
mechanical or electrical components, a re-calibration may be necessary.
To always achieve constant precise results during operation, in some special cases the machine needs to
be re-calibrated after some time.
The instructions in this chapter must be carried out by technical specialists!
11.8.1 Setting the blades
WARNING
Risk of injury on the blades!
The blades mounted on this machine have razor sharp edges, which can cause
serious injury if not handled properly during the blade change procedure.
Do not touch the knives.
Adjusting the blades is necessary with the following criteria:

■ Blades new
■ Cutting fine material
■ Blade worn-out
1.▹ Switch off and unplug the machine from the mains- and the air pressure supply.
2.▹ Open and unhinge the safety door, then lay aside.
3.▹ Loosen the four screws (1) on the ejection
chute.
4.▹ Disassemble the ejection chute (2).
1 1
5.▹ Move the wire guides (3) all the way to the
right.
6.▹ Loosen the tree screws (4), so that the wedge
(5) can be moved to the left. 3

7.▹ Manually move the upper anvil (6) down-

6
wards.
➥The upper blade should not touch the lower
one thereby.
8.▹ Position the wedge (5) centered.
9.▹ Screw on the lower blade somewhat with the
tree screws (4).
5
10.▹ Manually move the upper anvil (6) upwards.

6
11.▹ Screw on the lower blade with the three
screws (4).
12.▹ Manually move the upper anvil (6) up and

down. 6
➥The blades must just not touch each other.
13.▹ If the blades jam, move the wedge (5) to the

left somewhat.

14.▹ Move the upper anvil (6) up and down man-

ually and cut a fine paper-strip (7) to inspect
the setting.
15.▹ If the blades do not cut the paper then move

the wedge (5) somewhat to the right.
16.▹ Repeat above procedure until the blades cut
the paper properly.
17.▹ Tighten the screws (4) finally.
5
18.▹ Mount the ejection chute.

19.▹ Mount the safety door and close it.
20.▹ Connect the machine to the mains and the air pressure supply.
22.▹ Perform a functional check.
The blade adjustment procedure with the paper-strip should only be performed with standard applica-
tions. With difficult processable cutting material, perform the cutting checks with the appropriate materi-
al.
11.8.2 Configuring the machine
WARNING
Any changes in the screen „Configuration PowerCut 3700“ affects the behavior of
the machine and should only be handled by experienced and trained personnel.
This menu item is only accessible for persons with password level „Service“
Contact your local Schleuniger representative.

5 3.▹ Select [1] „Level“.
4.▹ With [@] select the password level "Service".
5.▹ [ENTER]
6.▹ Enter the "Service" password.
7.▹ [ENTER]
8.▹ 2 x [MENU]

9.▹ From the main menu select the screen „Configuration“ with the key [3].
3-3 10.▹ Press [3] "Product name" (this screen contains all the machine settings for the PowerCut 3700).
11.▹ Display contrast: Adjust to the light condi-

tions in the room.
12.▹ Gap resolution: Set the amount of pulses for
the gap sensor.
13.▹ Gap home: Set the home position (Measure
distance in-between the opened feed belts
and enter the value in mm).
14.▹ Gap position: In the entry field enter the con-
tact pressure (steps from 0–9). Subsequently
press [CLOSE]. The transport unit closes until
the contact pressure is reached. Contact pressure
The value (Voltage, V) in the screen inform
about the function of the gap sensor, see table
bellow.
Than open the transport unit again with
[OPEN].
15.▹ Feed resolution ( Feed resol.): One encoder
pulse equals this travel in mm respectively in
inches.
Gap position, voltages:
Value (V) State Belts

approx. 1.35 in operation open
> 2.60 defective closed
< 1.20 defective closed
11.8.3 Setting back to factory default

If a fault condition occurs on the PowerCut 3700 always proceed first according to chapter "8.7 Diagnostics
(Page 53)".
Not until a detailed labor trying to bring the PowerCut 3700 into operation again, the option of switching
the whole machine back to their factory settings may be considered.
NOTICE
Caution property damage!
The function "Factory default" is only accessible for persons with password level
„Supervisor“.
All settings are put back to their factory settings.
Caution: All wire programs are deleted!
Contact your local Schleuniger representative.


5 3.▹ Select [1] „Level“.
4.▹ With [@] select the password level "Supervisor".
5.▹ [ENTER]
6.▹ Enter password.
7.▹ [ENTER]
8.▹ 2 x [MENU]
9.▹ Based on the main menu press the key [4]
4-1
"Diagnosis".
10.▹ [1]Info.
11.▹ Press the following key combination, to get
access to the screen "Back to factory defaults".
12.▹ [SINGLE]
13.▹ [DEL]
14.▹ [ENTER]
15.▹ [3] „f“
16.▹ [2] „a“
17.▹ [2] „c“
18.▹ [8] „t“
19.▹ [6] „o“
20.▹ [7] „r“
21.▹ [9] „y“
22.▹ [OK]
23.▹ The machine restarts in the native state.

11.9 MAINTENANCE / REPAIR WORK
11.9.1 General / safety
The instructions in this chapter must be carried out by technical specialists!
WARNING
Electric current!
For any maintenance and repair work on the machine, it must be turned off,
locked against switching on again and the power cord must be removed. Dan-
gerous line voltage is present inside the machine and around the area of the
mains socket, which can lead to serious injury or death if disregarding.
NOTICE
Observe the guidelines after replacing components!
Disregarding of the following guidelines may lead to malfunction or damage on
the product.
■ After each replacement of a defective component, make sure that all the
adjustments are taken over.
■ An upgrade of the software has to be carried out necessarily.
■ The user must necessarily follow the separate description if not stated in this
manual.
NOTICE
Electrostatic sensitive components!
Touching components which react sensitive to electric discharge (ESD) may lead
to malfunction and damage on the product.
■ Always handle ESD-components properly.
■ During replacement of PCB's wear a safety wrist strap to deflect the electric
charge.
Before disassembly a component we recommend to make a drawing or to take a picture of the part. This
is helpful, especially if the repair work takes longer.
11.9.2 Lubrication

NOTICE
Caution, property damage!
Inappropriate- or improperly used lubricants may lead to serious property dam-
age on the product.
Only use the supplied lubricant according to the available instructions. Please
also consider the information about the lubricating grease in the "Appendix".
Drives
On the PowerCut 3700 most of the drives and bearings are of a maintenance-free design. Lubrication only
is necessary in exceptional cases.
Applicable lubrication grease: Microlube GBU-Y 131

11.9.3 Replacing blades
WARNING
Risk of injury on the blades!
The blades mounted on this machine have razor sharp edges, which can cause
serious injury if not handled properly during the blade change procedure.
Do not touch the knives.
chute.
1 1
5.▹ Move the wire guides (3) all the way to the
right.
4
6.▹ Loosen the two screws (4).
7.▹ Disassemble the upper blade (5) and take out

through the safety door of the machine.

8.▹ Loosen the two screws (6) and remove the

guiding bracket (7).
9.▹ Loosen the three screws (8).

10.▹ Disassemble the lower blade (9) and the 9
wedge (10) and take it out through the safety
door of the machine. 10
11.▹ Clean the blade area and blade seating (11) on

the blade holder.
11

12.▹ Rub off the lower blade (9) with an oily towel
and mount together with the wedge (10) to 10
the holder.
13.▹ Slide in the wedge (10) up to the default posi-

tion. The pin is then positioned centered to
the cutout.
14.▹ Tighten the screws (8) somewhat. 10
15.▹ Mount the guiding bracket (7) on the new

blade with the two screws (6).
16.▹ Guiding support and blade edge must flush.
Guide angle
Lower blade

17.▹ Rub off the upper blade (5) with an oily towel
and mount.
Push up the blade onto the anvil and the two
screws (4) at the same time.
18.▹ Adjust the blades, see chapter "11.8.1 Setting
the blades (Page 69)".
5

11.9.4 Replacing transport belts
chute.
1 1

Upper transport belt:

4
5.▹ Push down the rubber washer set (3) on the
right. 3
6.▹ Loosen the straining screws (5) to release ten-
sion on the belt with the enclosed special 5
Allen key, by accessing through the holes (4)
on the side of the housing.
➥The transport belt is released.
7.▹ Unscrew the straining screws (5) fully.
8.▹ Loosen the four screws (6) and the two (7).
9.▹ Disassemble the bearing plate (8).
6
8
10.▹ Remove the tension pulley (9).

11.▹ Pull off the transport belt on the right, diago-
nal from the pulley.

12.▹ Insert the new transport belt.

13.▹ Slide in the tension pulley (9).
14.▹ Slide the bearing plate (8) onto the shafts and
screw on with the screws (6) and (7).
15.▹ Mount the straining screws (5) and tension the

transport belt evenly.
➥The tension force is correct, if the belt just
touches the center pulley.
Tip: Tighten the front faced straining screw (5),

until the transport belt touches the center pulley.
Continue with tensioning for half a turn. Tighten
the back straining screw (5) until the feed belt is
forming an even surface.
Lower transport belt:
16.▹ Loosen the two screws (10).
10

17.▹ Remove the guidance bracket (11) on the bot-

tom blade.
11
18.▹ Loosen the straining screws (5) to release ten-

sion on the belt with the enclosed special
Allen key, by accessing through the holes (12)
on the side of the housing.
➥The transport belt is released.
12
19.▹ Unscrew the straining screws (5) fully.
20.▹ Loosen the four screws (6) and the two (7).
21.▹ Disassemble the bearing plate (8).
7

22.▹ Remove the tension pulley (9).
23.▹ Pull off the transport belt on the left, diagonal

from the pulley. Simultaneously slide the belt
beyond the lower sheet edge by the help of a
flat tool (e. g. a screw driver).
24.▹ Insert the new transport belt in opposite direc-
tion.
25.▹ Slide in the tension pulley (9).
26.▹ Slide the bearing plate (8) onto the shafts and
screw on with the screws (6) and (7).
7

27.▹ Mount the straining screws (5) and tension the

transport belt evenly.
➥The tension force is correct, if the belt just
touches the center pulley. See Tip „Upper
belt“.
28.▹ Mount the guiding bracket (11) on the new

blade with the two screws (10).
11
29.▹ Guiding support and blade edge must flush.
Guide angle
Lower blade


12. Spare parts / exploded view drawings
11.9.5 Exchanging mains fuses
1.▹ Switch off and unplug the machine from the

mains supply.
2.▹ Unlock the fuse holder with a screwdriver and
remove it from the power supply module.
3.▹ Insert the new fuses into the fuse holder slots.
On a fuse change always replace both mains fuses

(same type and rating), see chapter "4.4 Rating plate
(Page 21)".
4.▹ Attach the fuse holder to the power supply

module.
5.▹ Connect the machine to the mains and switch
it on.
SPARE PARTS / EXPLODED VIEW DRAWINGS

For original Schleuniger spare parts see „Parts Catalog“.

12. Spare parts / exploded view drawings

13. Decommissioning / disposal
DECOMMISSIONING / DISPOSAL
13.1 DECOMMISSIONING
To decommission the machine proceed as follows:

2.▹ Switch off the main switch on the back side of the machine.
3.▹ Disengage the emergency stop button.
4.▹ Unplug the machine from the mains and remove the power cord.
5.▹ Reduce the pressure on the valve, remove the hose and keep it.
6.▹ Remove all interface cables connected to the peripheral devices and keep them.
13.2 DISASSEMBLY / RECYCLING / DISPOSAL

Disassemble the machine appropriately. Dispose of the disassembled parts according to the local legal
requirements of recycling.
Schleuniger machines mainly consist of the following materials:
Material Disposal
Aluminum Scrap metal
Steel Scrap metal
Other metal Scrap metal
Electro material Electronic waste
Plastics Recycling
NOTICE
Built in backup battery!
The battery contained in this product is made of heavy metals which are harmful
to the environment.
■ The battery is hazardous waste.
■ Recycle the battery.

13. Decommissioning / disposal

14. Appendix
APPENDIX
14.1 SOFTWARE UPGRADE

Here we describe how the Software of the PowerCut 3700 is updated by means of the Schleuniger Soft-
ware „Iguana“.
What is necessary:
■ PowerCut 3700
■ RS-232 wire (02:01 AM, receptacle (female) both sides)
■ Schleuniger software „Iguana“
■ Upgrade files (according to product):
● PowerCut 3700 _VX.XX_Std.hex (Standard-language package)
● PowerCut 3700 _VX.XX_East.hex (East language package)
14.1.1 Installing Iguana

■ Download the file Setup_Iguana_XXX.zip from the Schleuniger web page "www.Schleuniger.ch"
and unpack it in a temporary folder.
■ Double click on the file Setup_Iguana_XXX.exe. The installation of „Iguana“ is executed auto-
matically.
14.1.2 Downloading upgrade file

■ Download one of the following upgrade files from the secured section "www.Schleuniger.ch" (accord-
ing to product).
● PowerCut 3700 _VX.XX_Std.zip (Standard-language package)
● PowerCut 3700 _VX.XX_East.zip (East language package)
■ Save the file to the folder „Upgrade“ of the software „Iguana“, C:\Programs\Iguana\Upgrade.

14. Appendix
14.1.3 Upgrade procedure
1.▹ Connect the PowerCut 3700 with the RS232

cable between the D-sub 9-pin connector and
the COM-interface on the computer (PC or
Notebook).
2.▹ Switch on the PowerCut 3700.
3.▹ Start the IGUANA.exe application.
4.▹ Press the key [DATA EXCHANGE] (1).
5.▹ If the PowerCut 3700 is connected to „Igua-

na“ the first time, a dialog box appears where
the machine serial number can be entered.
6.▹ Enter the machine - serial number (2) without
the year.
7.▹ [OK] (3).
8.▹ The check box „Execute uploaded program”

(4) should be activated. This enables the
machine software to be started automatically
after the upgrade.
9.▹ [UPGRADE] (5).
10.▹ Select the desired upgrade file from the file
browser (6).
11.▹ [OPEN] (7).
12.▹ The upgrade process is started automatically.

The progress is shown in the window (8).

14. Appendix
13.▹ If the info box „Upgrade successful completed!

“ pops up, the upgrade process is finished.
14.▹ [OK] (9).
15.▹ The PowerCut 3700 starts the machine soft-
ware automatically.
14.2 CONNECTOR HS / PF
14.2.1 For use with a PreFeeder

With Schleuniger PreFeeders the appropriate connection cable is delivered with the Prefeeder. As per the
following diagram, the D-sub-connector can be self-wired by a qualified technician.
PreFeeder HS/PF interface
PFOUT
+24 VDC
S1 PFPRESENT
PFREADY
GND
D-Sub 15-pin (F)
Fig. 6: Connecting a PreFeeder
Input „PFREADY“, Pin 10 & 11:

If the D-sub connector is plugged in and the control contact S1 closed, the machine can be started nor-
mally. By opening the contact S1 the automatic operation is interrupted and the error message "PreFeed-
er blocked" is shown up on the display. After closing the contact S1 again, the program can be continued
with [RUN].
Output „PFOUT“, Pin 14 & 15:

This output is set to open collector (ground potential) during processing. This means the output is held
active. It is dimensioned for inductive loads up to 0.2 A at 24 VDC (relays, valves) and is protected against
stress peaks.

14. Appendix
14.2.2 For use with a HotStamp

The Schleuniger HotStamp devices are shipped with their appropriate connection cable. As per the follow-
ing diagram, the D-sub-connector can be self-wired by a qualified technician.
HS/PF interface
HotStamp
HSINPUT
+24 VDC
HSOUT
+24 VDC
D-Sub 15-pin (F)
Fig. 7: Connecting a PreFeeder
Input „HSINPUT“, Pin 4 & 5:

When operating a wire marker through this input, the wire feeding on the PowerCut 3700 is stopped until
the marking process is terminated.
Output „HSOUT“, Pin 1 & 2

The wire marker is operated through this output. It is dimensioned for inductive loads up to 0.2 A at
24 VDC (relays, valves) and is protected against stress peaks.

14. Appendix
14.3 PRE-/POSTFEED INTERFACE (PPI, OPTION)

On the postfeed connector a Schleuniger CableCoiler or WireStacker or a customer specific device may be
hooked up, see chapter "14.3.1.1 POSTFEED connector (Page 93)".
NOTICE
Interface overloading!
With inappropriate use of the interface, overload situations may occur which are
not covered by the internal protection circuitry. This can lead to damage to the
interface and / or malfunction to the product.
Basically the interface is protected against overload, short circuit, electrostatic
discharge and electromagnetic interference. Only operate the interface with the
in the technical data stated values.
14.3.1 POSTFEED interface
POSTFEED connector
POSTFEED
RENCA
RENCA
RENCB
RENCB
Gnd
+24 V
ROUT3/CCEJECT/WSEJECT
RIN3/CCREADY/WSEJECTREADY
ROUT2/CCBINDING/WSBATCH
RIN2/CCSTART/WSBATCHREADY
ROUT1/CCSTOP/WSCONVEYOR
RIN1/WSCONVEYORREADY
ROUT0
RIN0
Gnd
RDETECT
Gnd
WSEJECT passive
+24 V
Shield
D-Sub 25-pin (F)
Fig. 8: Pin assignment „POSTFEED“
Pin Description Function Signal type

1 + 24 V - Supply -
2 /WSEJECT passive Output for the ejection control of passive Wire- Output NPN
Stackers
3 - (not implemented) - -
4 RDETECT Wire sensing Input NPN
5 RIN0 Multifunction input Input PNP

14. Appendix
Pin Description Function Signal type

6 RIN1 Multifunction input Input PNP
/WSCONVEYOR- Input for acknowledgment from WireStackers PNP
READY
7 RIN2 Multifunction input Input PNP/NPN
/CCSTART Input for acknowledgment from CableCoilers PNP
/WSBATCHREADY Input for acknowledgment from WireStackers PNP
8 RIN3 Multifunction input Input PNP/NPN
/CCREADY Input for acknowledgment from CableCoilers PNP
/WSEJECTREADY Input for acknowledgment from WireStackers PNP
9 + 24 V - Supply -
12 RENCB Impulse output for feed synchronization Output TIA/EIA-422
13 RENCA Impulse output for feed synchronization Output TIA/EIA-422
16 GND - Supply -
17 GND - Supply -
18 ROUT0 Multifunction output Output PNP
19 ROUT1 Multifunction output Output PNP/NPN
/CCSTOP Output to control a cable coiler PNP
/WSCONVEYOR Output to control a wire stacker PNP
/CCBINDING Output to control a cable coiler PNP
/WSBATCH Output to control a wire stacker PNP
/CCEJECT Output to control a cable coiler PNP
/WSEJECT Output to control a wire stacker PNP
23 GND - Supply -
24 RENCB Impulse output for feed synchronization Output TIA/EIA-422
25 RENCA Impulse output for feed synchronization Output TIA/EIA-422
Electrical specifications of the connectors

PNP inputs
The PNP-inputs are internally protected against electro static discharge. The inputs are galvanically cou-
pled to GND.

14. Appendix
Input
Fig. 9: Principle schematic diagram of the PNP inputs
Parameter Max. ratings Min. Typ. Max.

Positive switching threshold UIN_T+ 7.8 - 12.8 V
IIN_T+ 2.3 - 3.9 mA
Negative switching threshold UIN_T+ 4.8 - 8.4 V
IIN_T+ 1.3 - 2.4 mA
Hysteresis ΔIIN_T 0.3 - 1.2 mA
Min. input voltage UIN_MIN IIN_MAX ≥ -1 mA - 0,4 - - V
Max. input voltage UIN_MAX IIN_MAX ≥ 10.3 mA - - 28 V
Min. pulse duration tMIN 10 - - ms
Impulse withstand voltage UIN_SRG IIN_SRG ≤ 1 A - - 40 V
tIN_SRG ≤ 10 µs
NPN inputs
The NPN inputs are internally protected against electrostatic discharge. The inputs are galvanically cou-
pled to +24 V.
Input
Fig. 10: Principle schematic diagram of the NPN inputs

Positive switching threshold UIN_T+ 15.5 - 19.2 V
IIN_T+ - 2,4 - - 1,3 mA
Negative switching threshold UIN_T+ 11.2 - 16.2 mA
IIN_T+ - 3,9 - - 2,3
Hysteresis ΔIIN_T 0.3 - 1.2 mA

14. Appendix

Min. input voltage UIN_MIN IIN_MAX ≥ 8.1 mA - 0,4 - - V
Max. input voltage UIN_MAX IIN_MAX ≥ - 2 mA - - 28 V
Min. pulse duration tMIN 10 - - ms
Impulse withstand voltage UIN_SRG IIN_SRG ≤ 1 A - - 40 V
tIN_SRG ≤ 10 µs
PNP - Outputs
The PNP outputs are internally protected against short circuit, overload, over temperature and electro-
static discharge. The outputs are able to control ohmic and inductive loads.
Safety
Circuit
Output
Fig. 11: Principle schematic diagram of the PNP outputs

Output signal VOH IOUT ≤ 500 mA 22.1 23.3 25.2 V
VOL IOUT ∼ 0 mA 1.5 V
Output current IOUT All outputsa - - 500 mA
IOUT_TOT - - 1.35 A
Max. switching frequency fMAX - - 1000 Hz
Short circuit current b
IOUT_SC 0.6 - 1.2 A
Response time of the short cir- tSC 4 - 10 ms
cuit protection
Impulse withstand voltage VOUT_SRG IOUT_SRG ≤ 100 mA - - 57 V
tOUT_SRG ≤ 200 µs
a ) The sum of all the output currents of the PNP outputs must not exceed this value.
b ) Switching threshold for the short circuit protection. The thermal protection may trigger early in cer-
tain circumstances.
NPN outputs
The NPN outputs are internally protected against over temperature and electrostatic discharge. Short cir-
cuit and overload protection is handled directly through the over temperature protection circuitry. The
outputs are able to control ohmic and inductive loads.

14. Appendix
Safety
Output
Circuit
Fig. 12: Principle schematic diagram of the NPN outputs

Output signal VOH IOUT ∼ 0 mA - - - V
VOL IOUT ≤ - 300 mA 0.6 1.2 V
Output current IOUT All outputsa - - - 300 mA
IOUT_TOT - - - 1,80 A
Max. switching frequency fMAX - - 1000 Hz
Short circuit currentb IOUT_SC - 0,4 - - 1,0 A
Response time of the short cir- tSC - - - ms
cuit protection
Impulse withstand voltage VOUT_SRG IOUT_SRG ≤ 300 mA - 0,3 - 60 V
tOUT_SRG ≤ 100 µs
a ) The sum of all the output currents of the NPN outputs must not exceed this value.
b ) The NPN outputs are thermally protected against short circuit.
Synchronization signal
Synchronization signals are transmitted differentially according to standard ANSI TIA/EIA-422 (formerly
known as RS422). The signal behavior is based on the signals of an incremental encoder. The signals are
provided directly from the motor control circuit in the machine. The impulse frequency is proportional to
the feed rate of the PowerCut 3700. The feed direction (forward / backward) can be recognized by means
of the signal phasing.
The synchronizing signals of the PREFEED interface are synchronized on the left transport unit. E. g. if the
left transport unit stands still, no pulses are transmitted even if the right transport unit is moving. The
synchronizing signals of the "POSTFEED" interface are synchronized on the right transport unit ("LENCB",
"RENCA" and "RENCB" are identical).
Machine Peripheral device

Shield
Fig. 13: Circuit diagram synchronization signal (LENCB, RENCA and RENCB are identical)

14. Appendix

Output signal VOH RT = 100 Ω - 2.3 - V
VOL RT = 100 Ω 0.8 1.05 V
Balanced voltage VOD RT = 100 Ω 0.95 1.5 - V
Offset voltage a
VOC 1.3 - 1.8 V
Output current IOUT RT = 100 Ω - 12 - mA
Short circuit currentbc
IOUT_SC - - 200 mA
Impulse frequency at 1 m/s f1m/s Speed = 1 m/s - 5950 - Hz
Impulse frequency, max. fMAX - - 12000 Hz
Max. transmitting distance IMAX RT = 100 Ω - - 100 M
a ) Offset voltage VOC = (VOH + VOL) / 2
b ) Short circuit against GND over a certain period may lead to permanent damaging of the output cir-
cuitry.
c ) Short circuit against +24 V may lead to permanent damaging of the output circuitry.
Wire processing machine

LENCA / RENCA
LENCA / RENCA
LENCB / RENCB
LENCB / RENCB
t
Fig. 14: Signal sequence, wire transport direction forward
Wire processing machine

LENCA / RENCA
LENCA / RENCA
LENCB / RENCB
LENCB / RENCB
t
Fig. 15: Signal run, wire transport direction backward

14. Appendix
Supply outputs
Synchronization signals are transmitted differentially according to standard ANSI TIA/EIA-422 (formerly
known as RS422).
Machine
Fig. 16: Principle schematic diagram supply outputs

Output voltage VSUPPLY ISUPPLY ≤ 1.35 A 22.8 24 25.2 V
Output currenta ISUPPLY - - 1.35 A
Impulse withstand voltage UIN_SRG IIN_SRG ≤ 1 @IN_SRG ≤ 10 µs - - 40 V
a ) The sum of all the output currents of all supply connections.

14. Appendix
Protection against faults and malfunction

The +24 V outputs must not be connected to external power supplies.
Machine
Peripheral device
Shielding recommended for long cables
Controller Power supply

e. g. PLC
Fig. 17: Avoiding short circuit
To avoid ground loops it is recommended that the signal on the peripheral device is galvanically decou-
pled. This can be achieved through, e. g. relays or opto couplers (already available in most PLC‘s). In heavy
EMV loaded areas, we recommend the use of shielded connections.

14. Appendix
Machine Peripheral device
Galvanically isolated
Shield
Fig. 18: Galvanically decoupled signals
For transmission of synchronizing signals, the use of shielded cables is generally recommended.
Machine Signal converter Peripheral device
Galvanically isolated
Shield
Short distance
Fig. 19: Synchronization signal transmission

14.4
14. Appendix
102 | 118
Option
PF/PREFEED ROBOTIC INTERFACE
1
1
C
762002-0 Sensor Blade Position
D-Sub 25pol F D-Sub 25pol F
AC INPUT 694020-0 694021-0
Kabel PF/Prefeed Kabel Robotic Interface

N E L
Display
124 x 64 INKJET INTERFACE W S/POSTFEED
Gerätestecker
J1
1
1
Molex 2.54 10pol2

714027-0 Frontpanel 694018-0 D-Sub 25pol F D-Sub 25pol F
Cx
Erdkabel extern 694022-0 304016-0
L
L
Folientastatur Kabel Linear Hallsensor
Kabel Inkjet Interface Flachkabel Centronics
Cy
Cy
G
BLOCK DIAGRAM
3M 26pol5 3M 26pol3 3M 26pol 3M 26pol4

J4 J5 J7 J6
3M 16pol2 Pre-/Post Feed

694019-0 J2 652007-6
Kabel Pre/Postfeed
F2
F1
5AT 5AT
J2
J1
Molex 2.54 5pol 694000-1 KABELENDE
694014-0 3M 10pol
J5
J17
Kabel Netzverdrahtung RS-232 Kabel RS232 J15 Interface Servo B
694017-0
J6
Molex 2.54 2pol
3M 16pol1
Flachband
Flachband
692002-4 J24
1 1
Main Board SMC 26pol SMC 26pol Molex 2.54 5pol GAP
SUB-D 9pol male 672001-6 J3 J12 J21 Sensor Kabelende/ Gap
HOME
Molex 2.54 10pol1

694013-0 3M 16pol Molex 2.54 2pol
HS/PF Kabel HS/PF J25 J22
J1
J2
Molex 2.54 10pol
J4
J5
Molex 2.54 5pol

Molex 2.54 6pol
3M 10pol
Molex 3.96 2pol 694007-0
SUB-D 15pol female J8 Kabel Gap Motor GAP
MOTOR
V2 694010-0 Molex 3.96 2pol
J7
Molex 2.54 3pol 694006-0
Molex 2.54 5pol

J26
Molex 2.54 5pol
J16
Molex 2.54 2pol
J24
Molex 2.54 2pol
J20
Molex 2.54 5pol
J18
Molex 2.54 5pol
J19
3M 10pol
Output GND Kabel Netzteil 24V J28 J9 Kabel Encoder Gap
V1 Kabel Pre-Postfeed PC3700

Netzfilter
Netzteil GND 694009-0
694012-0 694023-0 694002-0
PE Sensor Cutter
Kabel Fusspedal Kabel Encoder Ausgang 694003-0 694015-0
IN N Kabel I/O
22
12
Kabel Messerventil
L
694004-0
6 Kabel Kommunikation
1
7
-
-
+
+
5 2
Kabel Servo-Netz 694016-0
4 3 D-A90L D-A90L
Not-Aus
22 21
12 11
CUTTER CUTTER
HOME DOWN
Fusspedal
Schmersalschalter
Schneidventil
21
11
Kabel Schmersalschalter
694011-0
Sicherheitsventil Messer
694005-0
694001-0 Kabel Motor Encoder
Kabel externer Notstop

TRANSPORT
MOTOR
L11
L21
Neutrik 3Pol
CN3
CN2
CN1A
CN1B
Versionen Gezeichnet Geprüft
Ind Rev Datum Vis. Datum Vis.
1 2 694008-0
0 1.0 21.10.05 brg 21.10.05 meh
3 0 1.1 20.06.06 brg 20.06.06 erk
L1 W 0 1.2 13.11.06 brg 13.11.06 erk
0 1.3 16.01.07 brg 16.01.07 erk
L2 Servo V PC 3700
0 1.4 20.04.07 brg 20.04.07 erk
Motor Transport 0 1.5 03.07.07 brg 03.07.07 mj
U Title Blockschema PC 3700 0 1.6 11.12.07 brg 11.12.07 bts
Size Document Number Artikel Nr. Rev 0 1.7 05.01.09 brg 05.01.09 erk
- - - - - -
A3 692000-0 405520 1.7 - - - - - -
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Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

14. Appendix
14.5 LUBRICATING GREASE MICROLUBE GBU-Y 131
SAFETY DATA SHEET

according to Regulation (EC) No. 1907/2006 - GB
MICROLUBE GBU-Y 131

Version 1.0 Revision Date 03.07.2014 Print Date 03.07.2014
1. Identification of the substance/mixture and of the company/undertaking
1.1 Product identifier

Product name : MICROLUBE GBU-Y 131
Article-No. : 017117
1.2 Relevant identified uses of the substance or mixture and uses advised against
Use of the : Grease
Substance/Mixture
1.3 Details of the supplier of the safety data sheet
KLÜBER LUBRICATION MÜNCHEN

Geisenhausenerstrasse 7
D-81379 München
Deutschland
Tel: +49 (0) 897876-0
Fax: +49 (0) 897876-333
E-mail address : mcm@klueber.com

Responsible/issuing person Material Compliance Management
National contact : Klüber Lubrication Great Britain Ltd.

Hough Mills, Northowram
Halifax, HX3 7BN
Great Britain
Tel: +44-1422-205115
Fax: +44-1422-206073
sales@uk.klueber.com
1.4 Emergency telephone number

0049 (0) 897876-700 (24hrs)
2. Hazards identification
2.1 Classification of the substance or mixture

Classification (REGULATION (EC) No 1272/2008)
Not a hazardous substance or mixture.

Classification (67/548/EEC, 1999/45/EC)
2.2 Label elements
Labelling (REGULATION (EC) No 1272/2008)
1 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

Additional Labelling:
EUH210 Safety data sheet available on request.
2.3 Other hazards
3. Composition/information on ingredients
3.2 Mixtures
Chemical nature : Mineral oil.
Synthetic hydrocarbon oil
barium complex soap
Hazardous components
Chemical Name CAS-No. Classification Classification Concentration
EC-No. (67/548/EEC) (REGULATION [%]
Index-No. (EC) No
Registration 1272/2008)
number
Benzenamine, N- 68411-46-1 R52/53 Aquatic Chronic 3; >= 1 - < 2.5
phenyl-, reaction 270-128-1 H412
products with 2,4,4-
trimethylpentene
For the full text of the R-phrases mentioned in this Section, see Section 16.
For the full text of the H-Statements mentioned in this Section, see Section 16.
4. First aid measures
4.1 Description of first aid measures

If inhaled : Remove person to fresh air. If signs/symptoms continue, get
medical attention.
Keep patient warm and at rest.
If unconscious place in recovery position and seek medical
advice.
Keep respiratory tract clear.
If breathing is irregular or stopped, administer artificial
respiration.
In case of skin contact : Take off all contaminated clothing immediately.

Wash off immediately with soap and plenty of water.
Get medical attention immediately if irritation develops and
persists.
Wash clothing before reuse.
Thoroughly clean shoes before reuse.
In case of eye contact : If eye irritation persists, consult a specialist.

Rinse immediately with plenty of water, also under the eyelids,
for at least 10 minutes.
If swallowed : If unconscious place in recovery position and seek medical

advice.
Keep respiratory tract clear.
Never give anything by mouth to an unconscious person.
Get medical attention if symptoms occur.
2 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

: Move the victim to fresh air.
: Rinse mouth with water.
4.2 Most important symptoms and effects, both acute and delayed
4.3 Indication of any immediate medical attention and special treatment needed
5. Firefighting measures
5.1 Extinguishing media

Suitable extinguishing media : Use extinguishing measures that are appropriate to local
circumstances and the surrounding environment.
Unsuitable extinguishing : none

media
5.2 Special hazards arising from the substance or mixture
Specific hazards during : Fire may cause evolution of:
firefighting Carbon oxides
Metal oxides
Nitrogen oxides (NOx)
5.3 Advice for firefighters

Special protective equipment : In the event of fire, wear self-contained breathing apparatus.
for firefighters Use personal protective equipment.
In the case of respirable dust and/or fumes, use self-contained
breathing apparatus.
Exposure to decomposition products may be a hazard to
health.
Further information : Standard procedure for chemical fires.
6. Accidental release measures
6.1 Personal precautions, protective equipment and emergency procedures

Personal precautions : Evacuate personnel to safe areas.
Use personal protective equipment.
Ensure adequate ventilation.
Do not breathe vapours or spray mist.
Refer to protective measures listed in sections 7 and 8.
6.2 Environmental precautions

Environmental precautions : Try to prevent the material from entering drains or water
courses.
Prevent further leakage or spillage if safe to do so.
Local authorities should be advised if significant spillages
cannot be contained.
6.3 Methods and materials for containment and cleaning up
3 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

Methods for cleaning up : Contain spillage, and then collect with non-combustible
absorbent material, (e.g. sand, earth, diatomaceous earth,
vermiculite) and place in container for disposal according to
local / national regulations (see section 13).
6.4 Reference to other sections
7. Handling and storage
7.1 Precautions for safe handling

Advice on safe handling : Do not breathe vapours or spray mist.
Avoid contact with skin and eyes.
For personal protection see section 8.
Smoking, eating and drinking should be prohibited in the
application area.
Wash hands and face before breaks and immediately after
handling the product.
Do not get in eyes or mouth or on skin.
Do not get on skin or clothing.
Do not ingest.
Do not repack.
Do not re-use empty containers.
These safety instructions also apply to empty packaging which
may still contain product residues.
Keep container closed when not in use.
Avoid inhalation of vapour or mist.
7.2 Conditions for safe storage, including any incompatibilities

Requirements for storage : Store in original container.
areas and containers Keep container closed when not in use.
Keep in a dry, cool and well-ventilated place.
To maintain product quality, do not store in heat or direct
sunlight.
Containers which are opened must be carefully resealed and
kept upright to prevent leakage.
Store in accordance with the particular national regulations.
Keep in properly labelled containers.
7.3 Specific end use(s)
8. Exposure controls/personal protection
8.1 Control parameters

Contains no substances with occupational exposure limit values.
8.2 Exposure controls

Engineering measures
Maintain air concentrations below occupational exposure standards.
4 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

It is recommended that all dust control equipment such as local exhaust ventilation and material
transport systems involved in handling of this product contain explosion relief vents or an
explosion suppression system or an oxygen deficient environment.
Ensure that dust-handling systems (such as exhaust ducts, dust collectors, vessels, and
processing equipment) are designed in a manner to prevent the escape of dust into the work area
(i.e., there is no leakage from the equipment).
none
Personal protective equipment

Respiratory protection : In the case of vapour formation use a respirator with an
approved filter.
Hand protection : For prolonged or repeated contact use protective gloves.

The selected protective gloves have to satisfy the
specifications of EU Directive 89/686/EEC and the standard
EN 374 derived from it.
The choice of an appropriate glove does not only depend on
its material but also on other quality features and is different
from one producer to the other.
The break through time depends amongst other things on the
material, the thickness and the type of glove and therefore has
to be measured for each case.
Eye protection : Safety glasses with side-shields conforming to EN166
Hygiene measures : Wash face, hands and any exposed skin thoroughly after
handling.
Protective measures : The type of protective equipment must be selected according

to the concentration and amount of the dangerous substance
at the specific workplace.
Choose body protection in relation to its type, to the
concentration and amount of dangerous substances, and to
the specific work-place.
Environmental exposure controls

General advice : Try to prevent the material from entering drains or water
courses.
Prevent further leakage or spillage if safe to do so.
Local authorities should be advised if significant spillages
cannot be contained.
9. Physical and chemical properties
9.1 Information on basic physical and chemical properties

Form : paste
Colour : beige
Odour : characteristic
Odour Threshold : No data available
pH : No data available
5 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

Melting point/range : No data available

Boiling point/boiling range : No data available
Flash point : not applicable
Evaporation rate : No data available
Flammability (solid, gas) : No data available
Lower explosion limit : No data available
Upper explosion limit : No data available
Vapour pressure : < 0.001 hPa, 20 °C
Relative vapour density : No data available
Density : 0.95 g/cm3, 20 °C
Water solubility : insoluble
Solubility in other solvents : No data available
Partition coefficient: n- : No data available
octanol/water
Auto-ignition temperature : No data available
Ignition temperature : No data available
Viscosity, dynamic : No data available
Viscosity, kinematic : No data available
Oxidizing properties : No data available
9.2 Other information

Sublimation point : No data available
Bulk density : No data available
10. Stability and reactivity
10.1 Reactivity
10.2 Chemical stability
No decomposition if stored and applied as directed.
10.3 Possibility of hazardous reactions
Hazardous reactions : No dangerous reaction known under conditions of normal use.
10.4 Conditions to avoid

Conditions to avoid : No conditions to be specially mentioned.
10.5 Incompatible materials

Materials to avoid : No materials to be especially mentioned.
10.6 Hazardous decomposition products
6 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

11. Toxicological information

11.1 Information on toxicological effects
Product
Acute inhalation toxicity : This information is not available.
Skin corrosion/irritation : This information is not available.
Serious eye damage/eye : This information is not available.
irritation
Respiratory or skin : This information is not available.
sensitisation
Germ cell mutagenicity
Genotoxicity in vitro : No data available
Genotoxicity in vivo : No data available
Carcinogenicity : No data available
Reproductive toxicity : No data available
Teratogenicity : No data available
Repeated dose toxicity : This information is not available.
Aspiration toxicity : This information is not available.
Further information : Information given is based on data on the components and

the toxicology of similar products.
Components:
Benzenamine, N-phenyl-, reaction products with 2,4,4-trimethylpentene :
Acute oral toxicity : LD50: > 5,000 mg/kg, rat, OECD Test Guideline 401
Acute dermal toxicity : LD50: > 2,000 mg/kg, rat, OECD Test Guideline 402
Skin corrosion/irritation : rabbit, Result: No skin irritation, Classification: No skin
irritation
Serious eye damage/eye : rabbit, Result: No eye irritation, Classification: No eye irritation
irritation
Respiratory or skin : guinea pig, Result: Did not cause sensitisation on laboratory
sensitisation animals., OECD Test Guideline 406
12. Ecological information
12.1 Toxicity
Product:
Toxicity to fish :
No data available
Toxicity to daphnia and other :
aquatic invertebrates No data available
Toxicity to algae :
7 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

No data available
Toxicity to bacteria :
No data available
Components:
Toxicity to fish : LC50: > 100 mg/l, 96 h, Danio rerio (zebra fish), OECD Test
Guideline 203
Toxicity to daphnia and other : EC50: 51 mg/l, 48 h, Daphnia magna (Water flea),
aquatic invertebrates Immobilization, OECD 202 T1
Ecotoxicology Assessment
Acute aquatic toxicity : Harmful to aquatic life.
Chronic aquatic toxicity : Harmful to aquatic life with long lasting effects.
12.2 Persistence and degradability

Product:
Biodegradability :
No data available
Physico-chemical : No data available
removability
12.3 Bioaccumulative potential
Product:
Bioaccumulation :
This mixture contains no substance considered to be
persistent, bioaccumulating nor toxic (PBT)., This mixture
contains no substance considered to be very persistent nor
very bioaccumulating (vPvB).
Components:
Bioaccumulation :
Due to the distribution coefficient n-octanol/water,
accumulation in organisms is possible.
12.4 Mobility in soil
Product:
Mobility : No data available
Distribution among : No data available
environmental compartments
12.5 Results of PBT and vPvB assessment
Product:
Assessment : This substance/mixture contains no components considered
to be either persistent, bioaccumulative and toxic (PBT), or
very persistent and very bioaccumulative (vPvB) at levels of
0.1% or higher.
12.6 Other adverse effects
8 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

13. Disposal considerations
13.1 Waste treatment methods

Product : The product should not be allowed to enter drains, water
courses or the soil.
: Waste codes should be assigned by the user based on the

application for which the product was used.
Contaminated packaging : Empty containers can be landfilled, when in accordance with

the local regulations.
14. Transport information
14.1 UN number
ADR
Not dangerous goods
IMDG
Not dangerous goods
IATA
Not dangerous goods
14.2 Proper shipping name

ADR
Not dangerous goods
IMDG
Not dangerous goods
IATA
Not dangerous goods
14.3 Transport hazard class

ADR
Not dangerous goods
IMDG
Not dangerous goods
IATA
Not dangerous goods
14.4 Packing group

ADR
Not dangerous goods
IMDG
Not dangerous goods
IATA
Not dangerous goods
14.5 Environmental hazards

ADR
Not dangerous goods
IMDG
Not dangerous goods
IATA
9 / 10

14. Appendix
SAFETY DATA SHEET

MICROLUBE GBU-Y 131

Not dangerous goods
14.6 Special precautions for user

No data available
14.7 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
Not available
15. Regulatory information
15.1 Safety, health and environmental regulations/legislation specific for the substance or
mixture
REACH - Candidate List of : This product does not contain substances of very high
Substances of Very High concern (Regulation (EC) No 1907/2006 (REACH), Article 57).
Concern for Authorisation
(Article 59).
Major Accident Hazard : 96/82/EC Update:

Legislation not applicable
15.2 Chemical Safety Assessment

This information is not available.
16. Other information

Full text of R-phrases referred to under sections 2 and 3
R52/53 Harmful to aquatic organisms, may cause long-term adverse effects in
the aquatic environment.
Full text of H-Statements referred to under sections 2 and 3.

H412 Harmful to aquatic life with long lasting effects.
This safety datasheet applies only to products originally packaged and labelled by KLÜBER
LUBRICATION. The information contained therein is protected by copyright and must not be
reproduced or amended without the express written approval of KLÜBER LUBRICATION. This
document may be passed on only to the extent required by law. Any dissemination of our
safety datasheets (e.g. as a document for download from the Internet) beyond this legally
required extent is not permitted without express written consent. KLÜBER LUBRICATION
provides its customers with amended safety datasheets as prescribed by law. The customer is
responsible for passing on safety datasheets and any amendments contained therein to its
own customers, employees and other users of the product. KLÜBER LUBRICATION provides
no guarantee that safety datasheets received by users from third parties are up-to-date. All
information and instructions in this safety datasheets were compiled to the best of our
knowledge and are based on the information available to us. The data provided are intended
to describe the product in relation to the required safety measures; they are neither an
assurance of characteristics nor a guarantee of the product's suitability for particular
applications and do not justify any contractual legal relationships.
10 / 10

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Index
INDEX
A F
Access protector 23 Fault localization 61
Accident prevention regulations 9 Feed speed 44
Activity direction 10, 11 Figure reference 10
Actual value not in range 62 File not found 62
Adapter 52 Function keys 39
Fuse holder 25
B
Bearing 75 G
Binding position 48 Ground potential 91
Blade area 66 Guidelines 11
blade blocked 62
H
C Hot stamp 26
Classifications 15 Hotline 65
Cleaning interval 66 HotStamp timeout 62
Commands 11 HotStamp/PreFeeder 25
Commissioning 29
Communication error 62 I
Connection cable 91
Iguana 89
Connector
Inductive load 92
- HotStamp 92
Info 53
- Prefeeder 91
Information 10
Control contact 91
Inspection 65
Cross reference 11
Intended application 14
Cutting axis-clamping pin 48
Interface connection cable 13
Internal wire guides 23
D Invalid name 62
Daily maintenance 66
Devices 50 L
Diagnostic 61
Language 53
Dimensions 19
Liability for damage 11
Disengage 24
Load displacement 18
Display 39
Lubricating grease 13
Disposal 10, 87
Drives 75
D-sub connector 91 M
Machine name 65
E Machine serial number 90
Magnifier 10
Ejection time 47
Main menu 44
Electrical specifications 94
Main power switch 25
Emergency stop button 23, 24
Maintenance 65
Emergency stop link 16
Maintenance unit air pressure 25
Emergency stop link unit 25
Marking 59
EN 60204-1 27
Marking device 54
Encoder 25
Marking time 26
Entry keys 39
Measure 11
Entry screen 43
Measures 19
Errors 65
Measuring unit 33, 53
Menu level 10
Menu screen 43

Index
N Safety door 23
Safety hood 16
Navigation keys 39
Safety interlocks 16
No more memory 62
Safety regulations 9
No pedal detected 62
Schleuniger distributor 65
No prefeeder 62
Screen titles 11
No wire 62
Second earth conductor 25
Numeric fields 43
Serial number 65
Numeric keypad 39
Signal names 11
Signal sequence 98
O Software 42
Operating personnel 10 Software upgrade 26, 89
Operator panel 23 Software version 65
Original spare parts 12 Standards 11
Supervisor 57
P Synchronization signal 97, 99
Password 56
Pedal 54 T
Pedal connector 25 Talcum 66
Peripheral 53, 54 Text fields 43
Peripheral devices 26 Third parties 11
Personnel older than 14 years 15 Third party 16
Pixel errors 54 Thrown out of balance 18
Postfeed 25, 93 Tip 10
PPI (option) 54 Toggle fields 43
Prefeeder 54 Topic 10
PreFeeder 26, 91 Total wires 53
Prefeeder blocked 62 Trademarks 11
Printing wheel edge 59 Transport fixations 17
Production keys 39 Transportation locks 30
Property damage 13
Protective equipment 16 U
Upgrade file 89
R Use of unverified spare parts 12
Raised leakage current 27 User 50
RAM corrupted 62 User level 57
Ramp (acceleration) 44
Rating plate 21 W
Re-calibration 69
Warning notice 13
Recycling 87
Waste 10
Registered trademarks 11
Windows® 11
Regular inspection 61
Wire entry 23
RS 232 interface 25
Wire entry guide 23
Wire feeding 92
S Wire marker 92
Safety barrier 16 Wire type 65
Safety cover 16 Wire/cable guide 66

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PowerCut 3700

Automatic Cutting Machine

Schleuniger AG Schleuniger, Inc.

Schleuniger AG Schleuniger Japan Co., Ltd.

Schleuniger GmbH Schleuniger Trading (Shanghai) Co., Ltd.

2 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

3 TRANSPORT / PACKAGING / STORAGE 17

Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700 3 | 118

3.3.1 The packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 INSTALLATION / FIRST COMMISSIONING 29

7 GENERAL HANDLING / OPERATION 35

4 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

8 OPERATION OF THE CONTROL SOFTWARE 39

9 OPERATION USING A MARKING DEVICE 59

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10.1.2 Behavior in case of an error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

11 MAINTENANCE / MAINTENANCE SCHEDULE 65

12 SPARE PARTS / EXPLODED VIEW DRAWINGS 85

6 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

14.2.1 For use with a PreFeeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700 7 | 118

8 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

Schleuniger AG Phone: +41 (0)33 334 03 33

1.2 MANUFACTURING DATE / PRODUCT TYPE

1.3 INFORMATION ABOUT THE OPERATOR'S HANDBOOK

1.3.1 Contents of the manual

Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700 9 | 118

Quick Start Card (optional)

1.4 GENERAL SYMBOLS AND LEGEND

1.4.1 References and hints

Tab. 1: General symbols used in this instructions

10 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

1.5 DECLARATION OF CONFORMITY

1.6 LIMITATION OF LIABILITY

1.7 WARRANTY STATEMENTS AND POLICIES

1.8 COPYRIGHT PROTECTION

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For further information, see chapter "14 Appendix (Page 89)".

1.9 SPARE PARTS

12 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

2.1 WARNING NOTICES

2.2 CAUTION PROPERTY DAMAGE

2.3 GENERAL SAFETY NOTES

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2.4 SOURCES OF DANGER / RISKS

2.5 INTENDED USAGE OF PRODUCT

2.6 SAFETY SYMBOLS

2.6.1 Safety symbols used in manual

14 | 118 Reference Manual |Edition 5.1 (05-2015) |PowerCut 3700

2.6.2 Safety symbols on the product

2.7 MODIFICATION AND RETROFITTING

2.8 PERSONNEL QUALIFICATION

2.8.1 Personnel classification

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2.9 PERSONAL PROTECTIVE EQUIPMENT

2.9.1 Eye protection

2.9.2 Ear protection

2.9.3 Protective clothes

2.9.4 Safety shoes