molex 63816-1900 User manual

Benchtop Electric Crimp Machine
Doc. No: 638161900 Release Date: 06-15-21 UNCONTROLLED COPY Page 1 of 25
Revision: A Revision Date: 06-15-21
BENCHTOP ELECTRIC CRIMP MACHINE
Operation Manual
Order No. 63816-1900

Benchtop Electric Crimp Machine
Doc. No: 638161900 Release Date: 06-15-21 UNCONTROLLED COPY Page 2 of 25
Revision: A Revision Date: 06-15-21
Table of Contents
1Introduction .............................................................................................................................4
1.1 Product Specification ..........................................................................................................4
1.2 Conformity ........................................................................................................................4
1.3 Use of the Operating Instruction ..........................................................................................5
2Safety .....................................................................................................................................5
2.1 Warning and Safety Precautions in this Operating Instruction ..................................................5
2.2 Safety Precautions .............................................................................................................6
2.3 Responsibilities ..................................................................................................................6
2.4 Designed Use ....................................................................................................................7
2.5 Predictable Misuse..............................................................................................................7
2.6 Hazardous Areas................................................................................................................7
3Shipment.................................................................................................................................8
3.1 Packing.............................................................................................................................8
3.2 Packing Contents ...............................................................................................................8
4Technical Description ................................................................................................................9
4.1 Operator’s Guide................................................................................................................9
4.2 Machine Identification....................................................................................................... 10
4.3 Technical Data................................................................................................................. 10
4.4 Operating Elements.......................................................................................................... 10
4.4.1 Touch Display............................................................................................................ 10
4.4.2 Reset Button .............................................................................................................10
4.4.3 Push Button ..............................................................................................................11
4.4.4 Foot Switch ...............................................................................................................11
5Transport and Storage ............................................................................................................11
5.1 Transport ........................................................................................................................ 11
5.2 Storage .......................................................................................................................... 11
6Installation and Commissioning ................................................................................................ 12
6.1 Installation......................................................................................................................12
6.1.1 Installation Plan......................................................................................................... 12
6.2 Foot Switch Connection ....................................................................................................13
7Setup and Modifications........................................................................................................... 13
7.1 Switching the Machine On and Off ...................................................................................... 13
7.2 Mounting the Tool Head or Adapter on the Machine .............................................................. 14
7.3Rotate the Tool Holder ......................................................................................................14
8Machine Operation .................................................................................................................. 14
8.1 Submenu ........................................................................................................................ 15
8.2 Check ............................................................................................................................. 15
8.3 Touch Control ..................................................................................................................16

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8.4 Counter .......................................................................................................................... 16
8.4.1 Piece Count Input ...................................................................................................... 16
8.4.2 Batch Size Entry ........................................................................................................ 17
8.4.3 Reset Counter ...........................................................................................................19
8.4.4 Change Quantity or Batch Size .................................................................................... 19
9Normal Operation or Production Operation ................................................................................. 19
9.1 Crimping Process with Tool Head (63816-1915)...................................................................19
9.2 Crimping Process with Adapter and Tool Head .....................................................................20
9.3 Crimp Head and Adapter Compatibility ............................................................................... 20
9.4 Available Adapters, Tool Heads and Die Sets ....................................................................... 21
10 Maintenance....................................................................................................................... 22
10.1 Maintenance Schedule ......................................................................................................22
10.1.1 Daily Maintenance......................................................................................................23
10.1.2 Monthly Maintenance.................................................................................................. 23
10.1.3 After 200,000 Cycles or Every 2 Years .......................................................................... 23
11 Troubleshooting and Fault Analysis........................................................................................ 23
11.1 Mechanical Errors and Disorders ........................................................................................ 23
11.2 List of Error Codes ........................................................................................................... 24
12 Decommissioning, Dismantling and Disassembly .....................................................................25
13 Disposal.............................................................................................................................25
13.1 Accessories for Follow-Up Orders .......................................................................................25
14 Manufacturing .................................................................................................................... 25

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Revision: A Revision Date: 06-15-21
1Introduction
1.1 Product Specification
The most common terminals on the market can be crimped using the benchtop electric
crimping machine and the exchangeable crimp tool system.
Interchangeable crimping dies or tool heads can be selected and installed on the electric
crimping machine according to the type of terminal to be crimped.
1.2 Conformity
The machine may only be used for the purpose specified in the operating instruction. The
manufacturers and suppliers will not be liable for any damages that may result due to the
machine being used for a purpose other than that for which it was intended. This is done
entirely at the user’s own risk.
The benchtop electric crimp machine is CE compliant. The original of the following
declaration of conformity is supplied together with the operating instruction of the machine.
Zutreffende EU
Richtlinien Applicable
EU directives
2006/42/EG Maschinenrichtlinie
Machinery Directive
2014/30/EU Richtlinie
Elektromagnetische
Verträglichkeit
Electromagnetic
Compatibility Directive
2011/65/EU Richtlinie RoHS
RoHS Directive
Angewandte
harmonisierte Normen
Applied harmonized norms
DIN EN ISO 12100; DIN EN ISO 13857;DIN EN
349; DIN EN 61000-6-2; DIN EN 60204-1; DIN EN
894 (1-4)
Wir erklären, dass die oben genannte Maschine in ihrer Konzipierung und Bauart
und in der von uns in Verkehr gebrachten Ausführung allen einschlägigen
Bestimmungen der Maschinenrichtlinie sowie den weiteren oben aufgeführten
Richtlinien entspricht. Die Schutzziele der Niederspannungsrichtlinie wurden
gemäß Anhang I, Nr. 1.5.1 der Maschinenrichtlinie eingehalten. Bei Änderungen
der Maschineverliert dieseErklärung ihre Gültigkeit.
We declare that the above-mentioned machine, with its design and type of
construction,as well as the produced version, meets all relevant regulations of the
Machinery Directive as well as the above-mentioned harmonized norms. The
protective directions of the Low VoltageDirectivehavebeenmet inaccordancewith
Annex I, Section 1.5.1 of the Machinery Directive. This declaration will lose its
validity in case of anymodifications.

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1.3 Use of the Operating Instruction
The operating instruction contains all information concerning operating elements, operation,
commissioning, and maintenance work as well as technical data.
The operation instruction must be constantly within reach of the benchtop electric crimp machine.
Every machine operator must read and understand the operating instruction to ensure safe and
efficient production with this piece of equipment.
The manufacturer and the distributor decline to accept any liability for damages that are incurred,
due to the fact that the instructions on the machine or in the operation instruction have been
disregarded.
The user is responsible for supplementing the operation instruction with any instructions resulting
from current national regulations for accident prevention and protection of the environment.
2Safety
2.1 Warning and Safety Precautions in this Operating Instruction
The following warnings and safety-related cautionary notices in the individual sections and chapters
alert you to various levels of danger:
DANGER
Identifies an imminent, serious, danger, which, if it is not avoided, will lead to serious
injuries or even to death.
CAUTION
Identifies a possible danger, which, if it is not avoided, will lead to serious injuries or even
to death.
ATTENTION
Identifies a potentially dangerous situation, which, if it is not avoided, can lead to medium
or minor injuries or material damages.
INFORMATION
If this information is not followed, it can lead to a deterioration of the operating procedure.
DANGER
Because of the risk of hand or finger injury, never try to reach into the machine before
having assured that the machine is disconnected from the electric supply. Disconnect the
electric supply before changing the adapter or dies.

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2.2 Safety Precautions
The benchtop electric crimp machine has been constructed according to state-of-the-art technology
and the acknowledged technical safety regulations.
When carrying out jobs such as installation, putting the machine into operation or setting it up,
operation, changing the conditions of use and the mode of operation or carrying out maintenance
and service jobs, it is important to observe the procedures for switching off the machine described
in the operation instruction.
Please observe the national regulations regarding the minimum age of the personnel operating this
machine. Allowing younger persons access to the machine is strictly prohibited.
Do not operate the benchtop electric crimp machine until you have studied and fully
understood all instructions described in this operating instruction.
Unauthorized modifications to the machine exclude any liability on the part of the
manufacturer or dealer for any damage resulting therefrom.
There is a residual risk of fingers being crushed. Never try to reach into the danger area
without safely disconnecting the machine from the electrical supply.
Before each startup, check that all safety devices and manufacturer-approved adapters or
tool heads are correctly fitted and functioning.
Set the voltage changer to the correct voltage.
This machine may only be operated with Molex mounted adapters, tool heads and dies.
The benchtop electric crimp machine may only be set up and operated in perfect technical
conditions, observing all safety regulations and considering any possible dangers.
In cases of a machine malfunction, production must be stopped, and the malfunction must
be fixed before continuing work with the machine.
Work with caution.
Only one person can work on or operate the machine at a time.
Only trained personnel can work on or operate the machine.
When working with the benchtop electric crimp machine, do not wear loose clothing, jewelry
or long, loose hair that can get caught in the machine.
2.3 Responsibilities
The benchtop electric crimp machine may only be operated by suitably trained and authorized
personnel. The user must clearly define and observe the responsibilities for operation, setup,
maintenance, and service. It is particularly important to define who is responsible for work on the
equipment. Such work should only be carried out by specially trained staff.
Should the user make any changes to the machine without consulting the manufacturers or the
suppliers, the latter will not be liable for any damage that may result.
The user of the benchtop electric crimp machine is responsible for making sure that all persons
involved in any way, either in the installation or in maintenance of the machine, have been
thoroughly trained on the system using this operating instruction.
The user is also responsible for the training of operators, and the instruction must include the
following aspects:
Purpose of the machine
Hazard zones
Safety rules and regulations
Functionality of the various components of the machine
Proper operation of the machine

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To assure full familiarization with the system, the training must be conducted in the native
language of the operators involved.
Staff Qualifications Required in Conjunction with the Use of the Benchtop Electric Crimp Machine
Installation
Setup
Instruction
Technical personnel with language proficiency in either English or German in addition to the native
language of the operator
Operation
Through qualified personnel trained as indicated above
Maintenance
Service
Technical personnel with proficiency in English or German
The safety instructions, warnings and precautions contained in the individual chapters must be
strictly observed by all users and operators.
2.4 Designed Use
Realization of crimp connections for conductors up to 6mm² (wire end ferrules up to 50mm2)
depending on the terminal design
The benchtop electric crimp machine is designed for use with the adapters or tool heads
described in section 9. The adapter or tool head should only be used with the tool heads or dies
specified by Molex. The benchtop electric crimp machine should only be used together with the
adapter, tool head and die sets for the preparation of crimp connections.
2.5 Predictable Misuse
Every application, except those mentioned in Section 2.4.
oUse of the machine for cutting
oUse of the machine for press-fitting
oUse of the machine for punching/ punching
oUse of the machine for embossing
2.6 Hazardous Areas
1. Hazardous Area: Area of interchangeable crimping dies and tool heads
Person at Risk: Operator
Type of Hazard: Hand injuries
2. Hazardous Area: Opened machine person at risk
Person at Risk: Installation engineer
Type of Hazard: Direct or indirect contact with movable parts of the machine
Hand injuries (cuts from sharp edges)
Hand injuries (risk of crushing)

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3Shipment
3.1 Packing
Upon receipt, carefully unpack the benchtop electric crimp machine
and check that you have received all components against the
packing slip, declaration of conformity and operating instructions.
Retain the original packaging for further dispatch and for storage, if
required.
Dimensions
Length: 560mm (22.5”)
Width: 350mm (13.8”)
Height: 340mm (13.4”)
Gross-Weight: Approximately 22 kg (49 lb.)
3.2 Packing Contents
Quantity
Description
1 pc
Machine (without adapter/tool head/dies)
1 pc
115 VAC Power cord for USA (with ground contact)
1 pc
Instruction Manual
1 pc
Declaration of Conformity
Optional Items
1 pc
Foot Switch with Protective Cover and Connection Cable
1 pc
230 VAC Power cord for EU (with ground contact)
Figure 3.1

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4Technical Description
4.1 Operator’s Guide
Item
Description
1
Push button (right & left)
2
Reset button
3
Touch display
4
Holding device for tool
5
Socket for foot switch
6
Main plug connection
7
Fuse holder (fuse 2A slow)
8
Main switch
9
Changeover switch
10
Nameplate with serial number
11
Sticker “follow instructions”
12
Foot switch (optional)
4
3
2
1
12
6
7
8
9
5
11
10
Figure 4.1

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4.2 Machine Identification
Item
Description
1
Manufacturer
2
Machine Type
3
Serial Number
4
Article Number
5
Connection Values
6
Year of Manufacture
4.3 Technical Data
Description
Specification
Length
437mm (17.2”)
Width
261mm (10.3”)
Height
170mm (6.7”)
Weight with Foot Pedal
Approximately 23.2 lb.
Operating Voltage
115 VAC / 230 VAC
50/60 Hz
Power Consumption
250 VA
Cycle Time
< 1.5s
Crimp Force
15 kN Max.
Stroke
Approximately 12mm
Noise Level
< 69 dB (A)
Operating Temperature
15-45°C
Relative Air Humidity
90% Max.
4.4 Operating Elements
4.4.1 Touch Display
All operating keys and parameters for the operation of
the machine are displayed on the touch screen.
Note: Details of the data displayed on the menu can be
found under section 8.
4.4.2 Reset Button
If the crimp dies are blocked because of an operating or
handling error or incorrect insertion of a crimp contact, the
machine can be released as follows:
Press the reset button. See Figure 4.4.2.
The force is released from the tooling.
Push the tooling open, remove the damaged contact
and dispose of it.
Figure 4.2
Figure 4.4.1
Figure 4.4.2
RESET
BUTTON

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4.4.3 Push Button
There is a button to trigger the crimping cycle on the right and
left sides of the machine. See Figure 4.4.3.
4.4.4 Foot Switch
Optionally, a foot switch can be connected to the machine.
Pressing the foot switch triggers the crimp cycle. See Figure
4.4.4.
5Transport and Storage
5.1 Transport
CAUTION
Wear suitable safety shoes when transporting the machine.
The machine can be carried by hand. The benchtop electric crimp machine weighs approximately
12 kg (26.4 lb.)
To transport the machine over longer distances, use the original packaging.
5.2 Storage
Store the machine in its original packaging at 5-50°C and a maximum of 90% relative humidity.
Figure 4.4.3
PUSH
BUTTON
Figure 4.4.4

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6Installation and Commissioning
WARNING
In the event of defects or damage to the machine, it must be stopped immediately and secured
against unintentional or unauthorized commissioning.
The machine may only be assembled and connected by a person who fulfils the
requirements of section 2.3.
The machine may only be put into operation if it is in perfect technical condition.
If defects or damages are found on the machine, the machine may no longer be operated.
6.1 Installation
CAUTION
Wear suitable safety shoes when assembling the machine.
Adhere to the following when installing the benchtop electric crimp machine:
Place the machine on a level surface and ensure that it is stable.
Ensure that the surface is strong enough to support the weight of the machine. Ensure a
suitable table height.
Access to the machine control unit must be kept free.
Lay the foot switch and connecting cable in such a way that they do not present a risk of
tripping.
Ensure that the workplace is adequately lit.
6.1.1 Installation Plan
Figure 6.1.1

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Connecting to the Power Supply
CAUTION
Pay attention to the setting of the voltage selector switch. Incorrect setting may damage the
machine.
1. Set the voltage selector switch (1) to the correct
voltage (115 V or 230 V). See Figure 6.1.2.
2. Connect the external power supply (2) with the
applicable power cord.
6.2 Foot Switch Connection
INFORMATION
The foot switch can be ordered optionally and is not included in the scope of delivery.
1. Insert the coded connector plug of the foot switch into
socket 1. See Figure 6.2.1.
2. Turn the plug protection to the right (clockwise) to
lock it. Turn it to the left (counterclockwise) to
release it.
7Setup and Modifications
7.1 Switching the Machine On and Off
Switch it On
1. Set the main switch to position I. See Figure 7.1.
2. The user interface starts automatically.
Switch it Off
1. Set the main switch to position 0. See Figure 7.1.
2. The user interface shuts down.
1
Figure 6.2.1
1
2
Figure 6.1.2
Figure 7.1

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7.2 Mounting the Tool Head or Adapter on the Machine
DANGER
Switch off the machine at the main switch before mounting the tool head or adapter.
Use the following instructions to mount the tool head or adapter:
1. Switch off the machine.
2. Pull out the indexing pins (1) of the tool holder until they
stop.
3. Mount the tool head or adapter from above.
4. Re-lock the locking pins (1) of the tool holder.
7.3 Rotate the Tool Holder
WARNING
Switch off the machine at the main switch before rotating the tool holder.
It is possible to rotate the tool holder by 90
degrees. Use the following instructions:
1. Loosen the screws (1). See Figure 7.3.
2. Pull the tool holder upward, rotate by 90
degrees and reattach.
3. Tighten the screws (1).
8Machine Operation
The production screen is displayed when the
machine is switched on. All other menus and
functions can be called up from the
production screen.
Item
Description
1
Submenu
2
Software version (example)
3
Input field for entering the number of pieces
4
Reset (quantity/ lot size)
1
Figure 7.2
1
1
Figure 7.3
Figure 8.0
1
2
3
4

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8.1 Submenu
1. Click to change language between German and English
2. The check is only used to check or display individual elements.
3. In this menu item, the motor can be turned slowly forward or backward.
4. The service menu item is only accessible to the manufacturer of the machine and can be
activated by a protected PIN.
5. Return to the production screen by clicking the arrow.
8.2 Check
The Check can be used to check the function and status of the machine.
1. By pressing the left button, "0" becomes "1" on the display.
2. By pressing the right-hand button, "0" becomes "1" on the display.
3. By pressing the footswitch, "0" becomes "1" on the display.
4. By pressing the reset button "0" becomes "1" on the display.
5. This shows the amount of machine cycles.
6. This shows whether the angle sensor is connected.
Figure 8.1
1
2
5
4
3
Figure 8.2
1
2
4
3
5
6

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8.3 Touch Control
DANGER
Due to the risk of hand or finger injury, do not reach into the tool area while the machine is
moving. There is a danger of crushing.
To move the machine slowly forward or backward,
proceed as follows. See Figure 8.3:
1. By pressing the clockwise arrow (1), the
machine moves forward.
2. By pressing the counterclockwise arrow (2),
the machine moves backward.
3. If the button is no longer pressed, the
machine stops at this position.
8.4 Counter
This machine has a piece counter and a batch counter.
8.4.1 Piece Count Input
1. Select field 1by touching it. The quantity
screen appears. See Figure 8.4.1.
2. Enter the quantity and confirm with the OK button.
See Figure 8.4.2.
3. Use the arrow in the upper left corner to return to
the production screen.
4. If “0” is entered, the machine counts up without
limit.
Figure 8.3
1
2
Figure 8.4.1
1
Figure 8.4.2

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5. The entered quantity is displayed on the production
screen. See Figure 8.4.3.
6. When the required quantity is reached, an
information message appears on the display. See
Figure 8.4.4.
7. The crimping process can only be continued when
this is confirmed by clicking on the checkmark and
zeroing out the counter.
8.4.2 Batch Size Entry
1. Select field 1 by touching it. The piece
count input screen appears. See Figure
8.4.4.
2. Tap on the batch size field and enter the desired
quantity. Confirm the entry with the OK button. See
Figure 8.4. 5.
3. Use the arrow in the upper left corner to return to
the production screen.
Figure 8.4.3
Figure 8.4.3
Figure 8.4.4
1
Figure 8.4.5

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4. The production screen displays both the
calculated batch size (1) and the
automatically calculated quantity (2). See
Figure 8.4.6.
5. When the batch size is reached, an information
message appears on the display, which must be
confirmed by touching it. Only then can the crimping
process be continued. See Figure 8.4.7.
6. When the defined quantity is reached, an information
message appears on the display, which must be
confirmed by touching. See Figure 8.4.8.
7. The crimping process can only be continued after the
piece count has been subsequently zeroed out. See
Figure 4.8.9.
Figure 8.4.6
2
1
Figure 8.4.7
Figure 8.4.8
Figure 8.4.9

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8.4.3 Reset Counter
1. Tap on the areas indicated in Figure 8.4.10 to reset
the counters. The display will jump back to the last
lot.
8.4.4 Change Quantity or Batch Size
1. To change the quantity or batch size, the respective
selection highlighted in blue must be confirmed by
pressing the OK button. See Figure 8.4.11.
9Normal Operation or Production Operation
DANGER
There is a residual risk of hand or finger injury. Do not reach into the crimp area.
9.1 Crimping Process with Tool Head (63816-1915)
1. Open the dies by pushing down the lever (1) and holding it.
2. Insert the crimp contact into the open die, and slowly release the
lever. The contact is held.
3. Insert the wire into the terminal, and hold it firmly.
4. Press the left or right button or the foot pedal to initiate crimping.
5. Push the lever (1) down again, and remove the crimped contact.
Figure 8.4.10
1
Figure 8.4.11
1
Figure 9.1

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9.2 Crimping Process with Adapter and Tool Head
1. Insert the wire into the contact and hold it.
2. Insert the crimp contact and wire into the die.
3. Press the left or right button or the foot pedal to initiate crimping.
4. Remove the crimped contact.
9.3 Crimp Head and Adapter Compatibility
Modular crimp heads, power crimp heads, adapters and dies are easily and quickly interchanged
between hand crimp tools and the electric crimping machine. Refer to the following compatibility
chart:
Crimp Heads and Adapters for Hand Crimp Tools
Type 4A
Type 2C
Type 4C
Type 4D
Type 4E
Type AT
Type RHT
*See Note
63816-1950
63816-1915
63816-1915
63816-1920
63816-1940
63816-1930
64005-xx00+
63816-1930
Adapter
Head
Head
Head
Head
Adapter
AT Head
+ Adapter
63816-1900
Benchtop Electric Crimp Machine
*NOTE: Un-tooled AT heads are not available separately. Customers can install RHT tooling into
one of their existing AT heads.
Caution: frame markings on the AT head may not match the tooling nests from an RHT tool for a
different terminal.
Figure 9.2