Komax kappa 220 User manual

Operating
Instructions
Automatic
striPPing
machine
lsomnax koppo
220

Operating
Instructions
Automatic
striPPing
machine
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Art.No.
040986
-
Version
3

Publisher:
komax
AG
Industrrestrasse
6
CH-6036
Dierikon-Luzern
Phone041-455
0
455
Fax 041-450
15
79
Asof May
1996,
subiect
to change
Thereproduction
of
these
instructions
or
parts
thereof
,
inwhatever
form,
is
prohibitedwithout
theexpress,
written
permission
of
the
publisher'
3
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1996bykomax
AG,
Wire
Processing
Systems

Table
ofcontents
1.lntroduction
and
notes......... .....-'...'.."'
Page5
6
11Operatrng
instructrons
tOl)
1
2
l,lachrne
tdenttf
icat;on
1
3
-i-echnrcal
speciirca:rons
per'forrnance
range
1
4Accesso|es
'1
.5Personnel
quaiificalicns
and
tratntng
6
6
8
I
11
11
2.Safety
2.1
Explanatton
of
ncies
2 2 Safety
notes , .
? ? (:f otv faalrrroq
3.Transport
/ltems
included
inthe
delivery """""""""" 13
4.Overview
ofmachine """""""" 15
5.
Start-up
procedure 17
17
17
5 1Cfecks
pnor
tostart-uP
5.2Swrtch
on
and
otl
53
AClustments
and
seitings
prior
to
productton ....
..............
17
17
53.1
Stratghteier.
53.2
Punched
drsk
533
Feed
rolie.s
.
5.3.4
\/tre
gurdes
.
5
3.5
Biades
.. ...
53.5.1
Blade
tyPes
.
5.3.5.2
Cnangtng
the
blades
6.
Operating
themachine........'.....
6.1
Ccntrols
6.2
Dsplay
concept
'1
1
la
la
io
18
to
IJ
10
20
21
ai
al
22
6.3Snorl
overvievr
of
operator's
menus 23
24
24
6.4
lvlAlN
-
marn
men!...............
.
6.5
LANG
-language
selectron
..
Olkappa
220
-
Verston
3Table
of
contents

6.6
Brief
rnstructronsonthethreemostrmpodant
menus
6.6
1TEACH
-
programming
menu
6.6.2
PPARA
-
processparameter
menu
.
...,..
6.6
3PROD
- production
menu.
6.6
4Programming
example
.....
24
a+
26
27
G
J
G
2
J
J
-
6.7
PPARA
-
other
processtng
parameters
6.8TEACH
-Further
types
of
processing
.
6.8.1
lf/
-
Intermediate
stripptnq
6.8.2
PS
-
Stripprng
withmultiplecuts
6.8.3
Parameters
fordouble-sheath
processing
6.9
CONF
-
configuration
6.10
LIST
-
wtreltst
J
f
-
f
f
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J
30
32
33
34
JO
20
6.11
SEQU
-
sequence
menu
6.12
REMOT
-
remotemode
7.
Malfunctions
/error
messages
............ '.'....41
7.1Malfunctions
.......... ........-
41
7.2Error
messageson
thedisplay . .
.....' .... 42
8.Maintenance
/repair "'.'......'.....47
8..1
Maintenance........... 47
8.2
Determining
reference
positions ..
47
8.2.1
Feference
blades ......... ...47
8.2.2
Feferencedistance
(rollers) '. 48
8.2.3
Testfunctions ..................
48
9.Description
of
connections
................ ........49
9.1
Connectron
forsubsequent
processing ...... ...
49
9.2Connection
for
preliminary
processing 50
9.3Connection
forstop
inout ........
.......51
9.4Connection
forRS232
interface -........52
10.Listof
accessories
............ ..'..
53
1'1.lndex .............'.......
55
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Table
ofcontents Olkaooa220
-Version
3

1.lntroduction
and notes
Dear
Customer
The
komax
kappa
220
is an
automatic
stripping
machine.designed
to perform
the
following
wlre
nrocessinoaoolrcatrons
in
accordance
with
the
technicalspecif
icationslisted
in
Chapter
1.3:
'Y *tsr"".. -'
Thislistis
complete
please
readthe
operatrng
insiructions
caref
ully.
They
will
gurde
you
through
the
operatrons
ofthe
kappa
220
step
by
step
so
you
car
De
uslng
the
machine
successfully
in
nottmeatall.
Yours
trulY
komax
AG
e
G
a
Cuttrng
lo
lenoth
Strrpprng
wrth
half
Pull-off
Stripprng
with
fuli
oull-ofl
tr'*.rt1:t" ,_:
Multiple-step
cuttrng
(doublesheaths) #
H^t-at2mn markrnn
',ts '''.''''' Jre
Multi-core
wtres
Illl''"'"111"1__
Passive
wiredePcsit
system
tt
'u
o
Ribbon
cable
Ink-1et
rnarker
Wire
staci<er
Horizontal
and';ertical
strai
ghtener
PCsoflrvare
with
Wtndows
95 Microsoft
Windows95
Olkappa220
-
Versron
3 Introduction
and
notes

1.1
Operating
instructions
(Ol)
Theseoperating
instructions
apply
tothe
komax
kappa
220
-
software
versionF103b
andareavailable
rn
German,
English.
French.ltalian.
Spantsh
andPortuguese:
other
languages
areavailableon
request
Thorr cnnqrqt nf 67 n:r
_,,*3€S,
nUrnoereo
consecutlvety.
The
instructions
contain
complete
rnformation
onthe
controls.
theoperationoftheentire
machine.
maintenanceand
adlustmentsas
well
astechnicalspecificatrons.
Electricaldiagrams
anda Iist of
accessoriesarealso
rncluded.Theoperating
instructionsforthe
variousaccessoriesaredeliveredwith
eachdevice.
Makesuretheyare
not
lostwhen
thedevice
isunpackedandset
up.
The
operating
instructionsarean
integral
pad
ofthekappa
220.Keepthem
near
at
handso
you
can
readilyrefer
to
the
rnformationinthem
atanytime.
Theinstructions
must
beunderstoodandall
itemsin
them
followedbvanvone
responsiblefor
the
transport,rnstallation.
operationand
repair
of
themachine.
Payspecialattention
to Chapter2andthesafetynotesincluded
there.
komaxreseryesthe
right
tomake technicalchanges
in
thesystem
depictedand
indicatedin
these
instructions
if
suchchangesare
necessary
to
improve
the
komaxkappa.
lf
youneedadditional
copies
of
the
documents,
please
contact
your
komaxrepresen-
tative.
2
Y
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3
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1.2Machine
identification
Anameplatecontainrng thefollowrnginformationis
affixed
tothebackofthe
machine
Machrnetype Machine
number
Voltageversion Powerinput
fjq 1 1 Nameplateaffixedto the back ol the machine
1.3
Technicalspecifications/ performance
range
f
f,
C
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xt x6xz
Stripprnglengths Side
1
Strrpprng
length Pull-off length Side
2
Stripprng
lengthPull-off
length
rq!
pull
9lr
Half
pull-off
, Mullip]glcutstripprng
lntormodiaio qtrinn
_.,,r_rt-le
i sg.srt
99,9mm
40mm
. 36mm
.999,9mm
, 999,pqq
999,9mm
40mm
40mm
999,9mm
B0mm
40mm
40mm
40mm
f
r
]
T
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r.
r
lntroductionand
notes Olkappa
220
-
Version
3

LUr
19LrI rOrrys 1mm
-
99999mrn
Lengln
accuracy +r-
0.2?oor
1mm.
dependrng
on
the
wrre
Iength
Shorln
ode Length
ofremarnrnginsulation
<
50
mm
Remaining
insulation
=
wire
length
minusstripped
Iengths
Wirecross-secttons 0,06
-
6mm'
(stranded
wires)
AWG1O
-
AWG30
Ribboncable:up
to
12mm
rnwidth
Omm
Max o.rtsrde
dtameter
Pioco nrrtntrt qoo nr:nh lin 1 )
Preselectable
ptece
numbers 1
-
60
000
pieces
Noise
level:
Electrical
connecttons: 110Vt 15ol.
/ 50-60
Hz
230V
t 15ozo
/ 50-60
Hz
Dimensrons
(WxHxD) 480x340x390mm
Wergni 28kg
(without
deposition
untt)
''---- Standard
values
komaxkappa
220 i
"'".. )D'ocessed
wire
S
geec.
li).lc . nanian
r
/a
vbac
k.
FLFY05mm'
max.
35mm
0.2mm
I
-
r--
o
@
o
)o
I
t--
l
-+
l--
I -- --r
I
Olkappa220
-Version
3lntroductionand
notes
Tila wrre
length
lmml
lin 1 ? Piona nr rlnrt

1.4Accessories
Youcanuseany
ofa
numberof
accessones
tooptimize
the
komax
kappa
220to
your
specif
ic
application
while
remainrnqcompletelv
flextble
to
meet
futurerequirements
Wire
feedsystems: Variouswirefeedand
de-
reelrng
systems
Preliminary
wire
processing:
Ink-jetand
hot-stamP
marker
Wire
deposition
system:
Various:
t
?
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t
D
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f
f,
T
r
f
f
D
f
f
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D
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f
r.ln
l- .l 'l .'l
r PC
software
runsunder
Windows95
(required
for
ink-jetmarker)
I Setforribboncable processrng
r Set
for
parallelprocessing
Exte
rnal
strai
ghteners
(for
vertical
and
horizontal
posrtion)
2
!i--- ..:
":'-;
-J
ggx
gtrnl
r Large
assortment
of quick-re-
lease
gurde
parts
r Various
Vand
radius
blades
r Special
blades
and
wire
guide
parts
for
ribbon
cable
r Speoal
blades
and
wire
guide
parts
for
parallel
Processtng
-
?tr
.\t
i '\\'
I {i,
I
I
t
l
e.o.
hol
stamo-marker
komax24 komax
107
Wire
stacker
komax260 Wiredeoositsvstem
komax215
Refertothelistofaccessories
(Chap.
10)orthe
spare
parts
catalog
(Art.No.
041787)
forthecorresponding
article
numbers.
3
J
,
s
f
lntroduction
and
notes OlkaPpa
220
-
Version
3

1.5Personnel
qualifications
and
training
Machine
operator
Tne
machine
operaior
mustbe
familiar
enough
with
ihemachrnetobe
able
iooperaieit
piLrs
its
accessores
and
peripheral
units
withoutdifficulty
innormal
production.
Thrs
requrresa
good
understanding
ofthe
technicalaspectso{the
machineaswell
asaknowledge
of
the
software
for
operating
the
machine.
The
operator
can
attainthis
levelof
knowledgebyattendrng
komax'sLevelITrainingcourse.
In
the
course.
parlictPants:
I Bef
resh
and
enhance
their
basic
knowledge
ofthe
machtne
r Learn
about
thebastcs
of
operatrons
(software)
r Perform
oractical
procedures
onthe
machine
Training
courses
tailored
tocustomer
needs
t' Asrde
fromthetrarn
ing
courses
mentionedabove,
komaxalso
offers
LevelSTrainingcou
rsestocover
specific
needscustomers
may
have.
The
information
below
applies
toboth
levelsof
training:
:' I Duration: max.
3days
r Location: TrainingCenter
at
komaxDierikon
orin-house
atcustomer's
,: r Language: German
orEnglish
r Srzeof
group: Thenumber
oftraining
participants
rslimitedtoa
maximum
of3
, Olkappa220
-Version
3 Introduction
andnotes

Nofes
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2
3
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Olkappa
220
-Version
3
10

Z*\
\rI2
2. Safety
2.1 Explanation
of
notes
lnthe
noteooxes
throughout
these
instructions,
you
willsee
three
different
symbols
which
mustbe
obeyed
T^e
symbols
areuseC
as
follows:
This
symbol
indicates
asafety
note
lorany
work
procedureswhich
pose
adanger
of
injury
toyou
orolher
people.
Observe
these
warnings
and
proceedwith
special
care
in
these
instances.
Pass
these
warnings
on
toother
users'
This
symbol
isfound
next
toall
work
procedures
of
special
importance
in
preventing
damage
to
themachine.
Pass
these
safety
instructions
on
toother
users'
too'
This
symbol
marks
helpfultips
and
instructions
on
correct
proceduresand
behavior'
Observe
these
notes
caref
ully,
too.This
will
save
you
time
and
unnecessary
problems'
komax
AG
accepts
no
liability
whatsoever
ilmachine
users
disregard
the
instructions
marked
onthe
machine
or
in
these
instructions.
2.2 Safety
notes
Protection
from
Personal
iniurY
7} prior
toeach
start-up.
check
that
allsaf
ety
features,
especially
the
covers,
are
attached
..hllll andin properworkingorder.
Safety
features
may
be
removed
only
when
the
machine
isstopped
and
the
powerto
themachine
isswitched
ofl.
Housings
and
covers
in
particularmay
be
removed
only
byproperlytrained
personnel.
ltis
dangerous
totouch
current-carrying
parts
!
,|* Whenever
carrying
out
assembly,
maintenance
and
repair
work,
always
switch
off
the
.,Sf, entire
komax
kappa
and
secure
itagainst
unauthorized
switch-on.
Protection
for
the
machine
@
Thorough
training
ofthe
machine
users
is
the
best
way
to protect
the
machine
from
damage
since
disregarding
the
operating
instructions
can
destroy
parts
of
thesystem
'
This
tiaining
includes
reading
these
operating
instructions.
11
Olkappa
220
-
Verston
3Safety

Generalsafety
instruclions
J,
t
3
]
J
J
Only
authorized
and
trained
personnelfamiliar
with
kappa220safety
procedures
are
permitted
tooperate.
maintain
andservice
themachine.
lfthere
isreason
tobelievethatthemachinecan
no
longerbeoperated
safely,itmust
beshut
downand
securedagainstaccidental
switch-on.
Readthese
instructions
carefullyall
kappa
220tor
thefirsttime. theway throughbefore
operating
the komax
f
E
f
.
f
f
E
Asidefrom
theinstructions
inthismanual,always
observe
general
rulesofsafetyand
accident
prevention.
2.3
Safety
features
Mainswitch
formachine
Pressrngthe
marn
switch
ontherear
panel
of
the
machinecutsoff
the
power
supply
Emergency
stopswitch
Pressino the emeroencv stnn qwr'nh
on the frnnt oneratnr'snarlgl STOOSall maChine
I rErrilry rrrL ur rvJ r.vv
movementsandcutsoffthe
power.
Accessto controls
All
controlsare
readilv
accessrble.
Lownoiselevel:
less
than
75dBA
f
E
E
E
E
E
E
F
E
E
lD
E
E
F
I
f
F
r
@The
machinecan
bedangerous
ifimproperlyoperatedbyuntrained
personnel.
t.
j
12 Safety Olkaooa
220
-Version
3

3. Transport
/ ltems
includedin thedelivery
@When
transporting
the
komax
kappa,
observethe
instructions
below
as
wellas
general
rulesof safety
and
accident
prevention.
i"e xappa220
ts
pacKageo
r acarciboard box
Drmensions
of
theocx
(WxHxD):
60
x
44x48cm
Werght:
approx.
35kg
Always
observe
the
handling
symbols
on
the
package:
t
an'a
104'F )
\
Delicate
electronic
appliance
Do
not
stack
anything
on
thecover Keep
dry Fragile
Notethe
following
points
when
transporting
thesystem:
Always
transpon
tnesystem
careiully
to
prevent
damage
f
rom
impactor
careless
loading
or
unloading
lmmediaieiy
check
the
machtne
on
delrvery
foranytransport
damage.
Shortcomings
should
be
reported
rmmediately.
Items
included
inthe
deliverY:
Don't
use
hand
hooks Store
in
adry
Place
at
lessthan
40'C Keep
out of
direct
sunlight
ffi
<cmax
kaopa
220strrpper
withintegrated
vertical
straightener,
safety
cover
and
:assive
',^;,.9
lgPosli
svstem
Powercable
and
electric
fine-wire
f
uses
Set
of
V-blades
(2
blades)
Set
of
f
i'e rollers r4
rollers)
Swiveiirng
wire
guide.
6mm
\y'/rre
gurce,rtght.
6mm
Set
of
Allen
wrencnes
Blade
caltoratlon
wlres
operatrn
g
Instrucllons
Transport
Items
included
in
the
delivery
Olkappa
220
-Verston
313

Nofes
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Olkappa
220
-
Version
3
14

4.Overview
ofmachine
I
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i
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o
a ilof{)f
IJ (-(:ftrf,
- _ (D(D(E
utEt-
€ {::- 6t-Iffi
(DmE(E15lnm
lig4 1kappa220
fromabcve
1 Display
2 Function
keys
3 Keypad
4 Emergency
stopbutton
5 Wire
feed-in
6 Straightener
7 Punched
disk
8 Feed
roller
for
processing
side
1
9 Swivelling
wtre
gulde
{ n ^,,++;^^ h^^,
Iu vutul lg lluau
11 Wire
guide,
rtght
12 Shaft
forfeed
roller,
processing
stde
2
13 Trough
for
insulation
scraps
14 Wiredeposit
system
trough
15 Swrtch
for
raisrngthe
feedrollers
Olkaooa
220
-
Versron
3Overview
of
machine 15

0
n
l-e-f
o
lu.
tDl
lul
o
l
ia
t."
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l"A"l ,7^\
l(o) I Q/,
I.,\=r/oi i-
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Olo
rrl i xt x? w $r7 l
1t-.1
Srnnhl
;lLJl bF-d v-a v v l,*,
'tm;nt
ffi m,a, tlB
ll-lb-d rJ v I
xi x5 d I
fig4.2Backof
the
machine
J
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2
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=
J
2
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-
3
E
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3
f,
f
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t
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;
1 Mainswitch
2 Fuses
3 Power
connection
4 Connection
X2:subsequent
processtng
(e.g
5 Connection
X3:
preliminary
processing
(e.9.
6 Connection
X4:
reserve
7 Connection
X5:stop
input
8 Connection
X6:R5232-interiace
9 Connection
X7:reserve
10 Compressed
air
connection
11. Nameplate
12 Adhesive
lettering
forconnectors
wirestacker)
wire
marker)
Consult
Chapter
9 'Description
of connections'
ments. forinformation
onterminalassign-
16 Overview
ofmachine Olkaooa220
-
Version
3

5.Start-up
procedure
5.1Checks
prior
tostart-uP
Powerconnection:
Compressed
airconnection:
(used
toblow
away
insulatton
scraps)
- 110Vt 15%/50-60
Hzor23OV
* 159'o
I
50-60
Hz
Devrceswitches
overautomatically
- Lengthof
power
cabie2,5
m
- Use
aseoarate
mains
socket
I
Air
pressure
mustnotexceed
7bar
I
Compressed
air
f
ree
of
waterand
oil
fig5.2
Examcle
of
a strarghtener
r'v'th
I rollers
lnstallation
site:
5.2
Switch
on
andoff
Switch
onthe
machineatrnainswitch
1 on the
back
panei
ofthe
machine
lfnothing
happens,
check
tosee
if
the
emergency
stop
switch
onthe
front
operator's
panel
ispressed
inor iffuse2
underneath
the
mainswitch
rs
defectlve.
Afterstart-up,
the
lastactive
menuappears
inthe
preselected
language
5.3
Adjustments
and
settings
prior
toproduction
5.3.1Straightener
The
setting
shown
here
issuitable
for
mosttypes
ol wire.The imporlant
thrng
tsthatthe ma;or
straightening
ofthe
wire
takes
place
atthebegin-
ningofthestraightener,
allowing
thewiretosimply
run
outthrough
the
final
straightentng
roller
(xcy).
Adjustment
procedure:
Turn
the
retaining
screws
'1
and2 to adlustthe
inclination
of
the
straightening
rollers.
Closethestraightener
by
turning
eccentricthumb
screw
3
and
set
to
wtre
drarreter
onturnrng
scale
4.
- flat.
stable
and
non-vibratrngsur{ace
- protected
against
moisture
- moderateambtenttemperature
(not
too
hign
nor
too
low)
- ventilationslots
mustbekeptuncovered
- suf{icient
space
forwirefeed-rn
and
wiredepostt
systems
fig.5l Mainswitch
Eerci|W
t--
-
-
G
d
LJ
Olkappa220
-
Version
3Start-up
procedure 17

5.3.2
Punched
disk
Turnthe
punched
diskto
finda
wire
hole
that
is
neither
too
small
nortoo
large.
The
punched
drsk
needonly
becnanged
f
orspecialtypes
of
processtngtnvoiving.f
orexample,
ribbon
cableor
double
V-blades.
To
switchdtsk,
proceed
as
follows:
r Open
feed
rollersby
presstng
swttch1
r Femovetop
feedroller2
r Loosen
punched
disk3 byunscrewingscrew
4
withhexagon
socket
head
wrenchandremove
r Insertnew
punched
dtskand
retrghten
screw
r Flemountfeed
roller
fig5.3
Puncheddiskand
feed
roller
5.3.3
Feed
rollers
Usetheappropriate
typeof
feed
rollersforthewlretypebeing
processed.
To
change
rollers,
proceed
as
follows:
f
f
T
J
t
t
I
I
IJ
t
E
I
I
t
f
E
3
I
f
f
I
T
I
Openfeed
rollers
1
Loosen
f
astening
screws
2on
feedrollersand
pull
off
rollers
Slrdeonthe
appropriate
feed
rollers
for
the
wire
being
processed,
pushing
ttallthe
waytothestop
Prior
to
tightening
thescrews,
check
tomakesure
thescrews
are
pressing
against
surfaces3of
the
driveshafts;otherwtse
they
cculd
damagethe
shafts
r:n (6- tE-
Giz-r r;-
GGFI Gio-
I
I
5.3.4
Wire
guides.
Youmay
havetoadlustthe
swivelling
wire
guide
(in
frontoftheblade)and
the
right-hand
wire
guide
(behrnd
theblade)
depending
ontheoutside
diameter
ofthe
wire
being
processed.
Todoso,
proceed
as
follows:
Removeanydrawn-ln
truire
Pull
offtheswivelling
wire
gutde
1andattach
the
:nnrnnririo nrrido
*HH'"Y'
Make
surethe
gurde
hasa
{irm
axial
seat
on
the
swivelshaft.
Pull
offthe
right-hand
wire
gurde
2andattach
the
appropriate
guide.
I
f
t
I
I
T
t
I
t
T
t
r
;
fig.54Feedroller
fig.5.5
Guide
Parts
18 Start-uD
procedure OlkaPPa
220
-
Version
3

l{
there
is
axral
play
rnthe
gurde
pa11s,
loosen
hexagonnut3onball
thrust
prece4
(f
ig
5.6
and
5
7;
and
readjust
rt.After
adjustrng
rt
retrghten
the
nul
frg 55 Rrght-hand
wtre
gurde
,l
I
frg.5.7Swivelling
wtre
guide
5.3.5
Blades
5.3.5.1
Blade
tyPes
Standard
blades
t . V-blades
Thisblade
type
tssuitable
for
mostdiameters
and
types
ofwire.
Problems
wtth
stripping
the
remaining
insulation
canoccur
withcerlain
insulation
materrals
where
. I - : the
Vshape
does
notencompass
thestranded
wires
preclsely.
l'l
Radius
blades
These
biades
havearounded
cutttng
edge
and
are
adjusted
to
thecross
section
of
thestranded
wrres.
This
makes
rt
possible
to
process
wires
withextremely
thin
or
hard
1r7pes
of
'nsulation.
Custom-ordered
blades
"%' Blades
for
ribbon
cable
These
blades
can
beused
tostrip
ribbon
cable
withor
r,rrithout
intermediate
tie
Special
models
Custom
blades
for
special
wire
types
can
alsc
be
manufactured
on
requesl
Double
V-blades
The
piece
output
can
bedoubled
with
these
blades
Theyare
installed
lust
as
V-
blades
are.
Olkappa220
-
Version
3Start-uoDrocedure 19