molex RAST 5.0 User manual

RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 1 of 65
Revision: A Revision Date: 04-2 -09
RAST 5.0 SEMI-AUTOMATIC TERMINATOR MACHINE
For Appli-Mate™ Co ectors (12 a d 16 AMP)
Order No. 62300-6100
I structio Ma ual
 Description
 Operation
 Maintenance

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WARNING
NEVER USE THIS FIXTURE WITHOUT THE GUARDING OR OTHER SAFETY DEVICES
IN PLACE, GUARD DOORS CLOSED AND GUARD OVERRIDE SWITCHED
“OFF”.
FIXTURE GUARDING IS DESIGNED TO PREVENT HANDS FROM REMAINING
IN THE DANGER AREAS OF THE FIXTURE.
RUNNING THIS FIXTURE WITHOUT GUARDS, UNDER ANY
CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY.
NEVER OPERATE, SERVICE OR ADJUST THIS FIXTURE WITOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE
INSTRUCTIONS IN THE OPERATING MANUAL.
NEVER SERVICE THIS FIXTURE WHILE IT IS CONNECTED TO ANY ELECTRICAL
POWER SOURCE. DISCONNECT POWER BY SWITCHING OFF THE MAINS
ISOLATOR.
WORK SAFELY AT ALL TIMES
For Service, Co tact Your
Local Molex Sales Office
Molex Applicatio Tooli g Group
2200 Welli gto Court
Lisle, Illi ois 60532
Tel: [phone]
Fax: [phone]

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Table of Co te ts
SECTION
1. General Description
2. Start Up / Shut Down Procedures
3. Message Fault Display and Maintenance
4. Touch Screens and Troubleshooting
5. Assembly Drawings, Electrical and Pneumatic Diagrams
6. Connector Series Chart

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Sectio 1
Ge eral Descriptio
1.1. Description
1.2. Technical Specifications
1.3. Applicable Products and Wires
1.4. Delivery Check
1.5. Cє Certificate

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1.1 Descriptio
The 62300-6100 APPLI-MATE™ (RAST 5.0)
Semi-Automatic Terminator Machine, is designed
to terminate the APPLI-MATE™ (RAST 5.0)
female connector series (90 35, 91779, and
92000) onto discrete wire (1.0-1.5 mm2 and 16-1
AWG). This machine will accommodate circuit size
2 through 4.
1.2 Tech ical Specificatio s
Power Specificatio s:
To function correctly, these fixtures require the
following services:
Electrical Service
115/220 VAC 50/60 HZ 1 Phase 2 AMPS
P eumatic Service
6 BAR ( 5 psi) Minimum Clean, Dry and Filtered
Air Source
Pressure Gauge Setti gs
Main supply to machine - 6 BAR ( 5 psi)
1.3 Applicable Products A d Wires
Co ectors
Appli-Mate™ RAST 5.0 connector series 90 35,
91779, and 92000. See Connector Chart in
Section 6.
Wires
Conductor: 1.5mm², 1.0mm², 16AWG, and
1 AWG
Insulation outer diameter: 3.5mm maximum.
1.4 Delivery Check
Carefully remove this machine from its shipping
container and determine that the following items
are included in the package.
Order No.
62300-6100 Semi-Automatic Terminator
Machine for APPLI-MATE™
(RAST 5.0)
ATS-623006100 Instruction Manual
1.5 CE Complia ce
Complies with the ge eral health a d safety
requireme ts i accorda ce with:
-Council Directive 9 /37/EEC
-Council Directive 9/336/EEC and amended by 92/31/EEC
-Council Directive 73/23/EEC
This machi ery has bee desig ed a d
ma ufactured i accorda ce with the
followi g tra sposed harmo ised Europea
sta dards.
EN292: parts 1 and 2: 1991, Safety of Machinery-Basic
concepts, general principles for design.
EN294: 1992, Safety of Machinery-Safety distances to
prevent danger zones reached by the upper limits.
EN349: 1993, Safety of Machinery-Minimum gaps to avoid
crushing of parts of the human body.
EN41 : 1992, Safety of Machinery-Emergency stop
equipment, functional aspects- Principal for design.
EN60204 part 1: 1993, Safety of Machinery-Electrical
equipement of machines-Specification for general
requirements.

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Sectio 2
Start-Up / Shut Dow Procedures
2.1. General Operation
2.2 Machine Operation and Process Flow
2.3 Operator Set Up And Functions

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2.1 Ge eral Operatio
2.1.1 Prelimi ary
1. Connect air supply to fixture. Use 6mm nylon air hose in the quick-fitting.
2. Turn on mains power Isolator.
3. Release Emergency-stop push buttons if necessary.
2.1.2 System Start-Up (Whe above co ditio s are met)
1. Reset the power by pushing the Reset button.
2. Wait approximately 5 seconds for the air supply to reach operating pressure.
3. Home the sensor motor. See section 4.1 (screen 5).
4. Enter the circuit size. See section 4.1.
5. Press Start button.
2.1.3 Start-Up Followi g A Fault
1. Identify the fault on the touch screen.
2. Correct fault.
3. Reset the power by pushing the Reset button.
4. Wait approximately 5 seconds for the air supply to reach operating pressure.
5. Home the sensor motor.
6. Press Start button.
2.14 Start-Up After A Emerge cy Stop Or Guard I terrupt
1. Release Emergency Stops or close guard doors.
2. Press Reset button on operator panel.
3. Wait approximately 5 seconds for the air supply to reach operating pressure.
4. Home the sensor motor.
5. Press Start button on operator panel
2.1.5 Start-Up After A Power Failure
1. Release Emergency Stops or close guard doors.
2. Press Reset button on operator panel.
3. Wait approximately 5 seconds for the air supply to reach operating pressure.
4. Home the sensor motor.
5. Enter the Circuit size.
6. Press Start button on operator panel
2.1.6 System Shut Dow
1. Press the Emergency Stop button.
2. For extended periods of shutdown (i.e. Holidays), switch off the Mains Isolator.
CAUTION: NEVER OPERATE THIS FIXTURE WITHOUT GUARDS IN PLACE.

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2.2 Semi-Automatic Termi ator Machi e Operatio a d Process Flow
2.2.1 Co ector I feed
The strips of connectors are inserted into the adjustable locator. For operator instruction see section 2.3.
(operator set up and functions) The gripper then clamps the connectors and transports it into the next part of
the process, the cut station. This machine is designed to run one chain of connectors at a time. Connector
chains should not be stacked side-by-side.

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2.2.2 Co ector Separate (Cut Loose)
1. In the automatic mode the connectors are transferred to the cut station by the connector feed.
2. The cut support track automatically moves in behind the first row of connectors.
3. The cut blade separates the first row of connectors from the chain, so it can be fed to the next station.
(The connector feed remains forward until after the cut.)
4. Note: Cutting loose happens simultaneously with termination.
A Cut Loose Blade
B Cut Support Track
C Connector Feed Clamp
A
Clamping Cylinder
B Knurled Screw to tighten/release
the adjustable gripper jaw
C Rail Clamp Screw

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2.2.3 Co ector Tra sfer
1. After a row of connectors has been separated they are transferred to the termination position.
2. After a connector has been inserted with wires and has been terminated the finished assembly is
transferred out of the terminating station while the newly separated connector enters.
3. The connector transfer and the out feed are one motion.
A Transfer Cylinder
B Connecting Rod
C Transfer Rod
D Out Feed Pawl
2.2.4 Wire Feed (Mask Tooli g)
1. After the connector has been transferred from the cut station to the termination station the operator
manually inserts the wires into the connector.
2. This is aided by using a numbered plate (mask tooling) that slides down in front of the connector.
3. This slide centers the connector by engaging spring-loaded comb tooling from below.
4. The operator can then use the mask tooling to guide the wires into the connector. See Section 2.3.4
(operator set up and functions)
A Mask Tooling (numbered plate)
B Manually inserted wires

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A
Open Connector
B Termination Tool
A
Closed
Connector
B Termination Tool
2.2.5 Wire Se sor
1. A laser sensor detects that the wires are inserted to the proper depth in the connector.
2. According to the connector circuit size and corresponding program selected by the operator (See section
2.3.4) the machine detects when the correct amount of wires have been inserted successfully.
3. After all wires have been inserted successfully, the machine automatically terminates the connector.
A Laser Sensor to detect the wire position
in the connector.
2.2.6 Termi atio Statio
1. The connector is automatically terminated after all the wires have been inserted correctly.
2. The termination tool moves downwards and closes the connector, terminating the inserted wires.
3. At the same time a new row of connectors is being cut free from the chain.
4. The out feed pawl then removes the finished assembly to the end of the track.

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2.3 Operator Set-Up a d Fu ctio s
2.3.1 Machi e Ru
To Power Up
1. Turn on main disconnect switch on electrical
cabinet door.
2. Touch screen will reset.
3. Laser sensor motor will automatically home
itself or request operator to press home
button.
To Set Up (Touch Scree )
1. Press “Manual”
2. Press “Set up”
3. Select circuit size (2 - 4)
4. Select positions of wires to be inserted and
choose the language.
5. Press “main” to return to start screen.
To Load Co ector
1. Press “Manual “
2. Press “ Hsg Feed Grip”
3. Feed connectors manually to touch face of
cut station track blade. See section 2.3.3
4. Press “Hsg Feed Grip”
5. Press “Main”
To Start Ru
1. Press “ Start”
2. The first connector will be cut the fed to
termination position.
3. Mask tooling will lower.
4. Operator must manually insert wires into
connector. See section 2.3.4. Touch
screen will prompt the operator position of
each wire.
To Correct A I correctly I serted Wire
1. Cycle can be stopped if wrong wire is put
into wrong slot by pressing “REDO”
2. Mask tooling will rise allow removal of
wire(s). Note: other wires may fall out of the
connector and may need to be re-inserted.
3. Press “REDO” to restart cycle.
Note: A wire must be inserted for functions
“STOP” or “REDO” to be available on the
touch screen.
For detailed explanations of touch screens see
SECTION 4.
2.3.2 Material Supply
1. The connectors are supplied in continuous
chains and can be connected or
disconnected at the trailing end of the chain.
2. A sensor detects when the machine is
running low on connectors.
3. The operator then connects the upper
housing of the chain in the machine into the
lower housing of the new chain.
The operator MUST remove the first part of
the co ector at the begi i g of the strip
of co ectors to be fed i to the machi e.
The strips must begi with a complete
co ector.
A Removed when loading an empty machine
2.3.3 Setti g Up Co ector Feed
1. When circuit size is changed the connector feed
must be set up.
2. Adjust the guide rail to suit the width of the
connectors. This can be set up to 12 positions.
The rail can be moved by opening the clamp
screws and simply sliding the rail lightly against
the connector chain as shown. The connectors

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must be able to slide easily. Retighten the clamp
screws.
3. Loosen the knurled screw at the clamping
cylinder and slide the gripper jaw as far as
possible to the right.
4. Insert a strip of connectors into the machine
until they bottom out against the cut support
track.
5. Close the gripper jaw against the side of the
connectors and tighten the knurled screw.
6. Select the circuit size with wire quantity and
position on the touch screen and start the
machine. (See Section 2.3. )
A Cut Support Track
B Guide Rail
C Knurled Screw
D Gripper Jaw
2.3.4 Wire Feed
1. The Operator must manually insert each
connector circuit size with corresponding
number of wires.
2. As explained in Section 2.2.5 the operator uses
a numbered guide as an aid to insert the wires
into the connector. The touch screen prompts
the operator to the number slot on the guide to
place each wire.
3. After the operator has correctly inserted the wire
at the correct position an audio tone will sound,
an LED will illuminate, and the operator can
move to the next position (prompted on the
touch screen).
4. The mask tooling has spring loaded inserts
which will keep the wires held in position until
the connector has been terminated. After the
wire is inserted, do not attempt to pull the wire
out as the clamp grip may damage the wire. If
an insertion error occurs, it is best to use the
REDO function.
A Spring Loaded Wire Clamp
B Fully inserted Wire
2.3.5 Termi atio Shut Height Adjustme t
A Shut Height Fine Adjustment Screw
1. The termination shut height may be easily
adjusted from the front of the machine.
2. Use a 24mm open-end wrench and an mm hex
key to finely adjust the shut height.
3. The adjustment screw is situated at the front of
machine as shown.

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2.3.6 Program Selectio (Circuit Size)
1. When circuit size (or number of wires loaded)
changes, the program must be changed on the
touch screen.
2. The following procedure must be followed when
setting up for a new program and circuit size as
well as setting up new connector feed. See
section 2.3.2.
3. On the touch screen:
a. From Ready to Run. Press “Manual”
b. From Manual. Press “Set Up”
c. From Set Up. “Enter circuit size.” Keypad
will appear. Select desired circuit size (2-12
circuit). Size will be displayed on circuit size
line.
d. From Set Up. Press “Next”
e. Select Wire Positions 1-10. Press the
number and Y and N will toggle in the box
above the number. Y= Wire Present, N= No
Wire. Ensure that unused circuit positions
have N.
f. From Select Wire Positions. Press “Main” to
return to Ready to Run.
g. Press “Start” to run automatically.
2.3.7 Machi e Errors / Faults
The Operator is responsible for ensuring that
machine errors / faults are corrected immediately. If
the operator is unable to locate or resolve the fault,
they should seek assistance from the line
Technician.
See Section 4 for a full listing of faults.
2.3.8 Fi ished Product
The operator will ensure that the finished products
are removed from the end of the machine.

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Sectio 3
Message Fault Display a d Mai te a ce
3.1 Fault Displays
3.2 Maintenance
3.3 Perishable Tooling
3.4 Spare Parts

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3.1 Fault Displays
3.1.1 Name a d Fuctio s
Name Locatio Fu ctio
Emergency Stop
(Red Mushroom knob
on yellow background)
LH side of machine.
(Control Box)
To stop fixture immediately
as well as isolating the mains power
and air from the fixture.
Power On Lamp
(Green Lamp)
Centre of machine.
(Control Box).
To Indicate that the
machine is ready to run.
Reset Button
(Blue Switch)
LH side of machine.
(Control Box)
To connect mains power
and air to the machine.
3.1.2 Descriptio Of I dicators
Name I dicator Descriptio
LED (Green) Solid Green Wire inserted
Speaker Audible “beep” Wire inserted
3.2 Mai te a ce
3.2 1 Clea i g
The RAST 5.0 Semi-Automatic Terminator Machine should be cleaned at least once a day with a soft
brush to remove dust and debris.
CAUTION: Using compressed air to clean the Terminator is not recommended as debris could
become jammed in the tooling and/or come flying out at the operator
3.2.2 Lubricatio
The press requires regular lubrication on a monthly basis. Place a small amount of lubricant with Teflon,
such as Permatex “Superlube”, on the sliding surfaces.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your
Terminator or use this as a template to create you own schedule or use your company’s standard chart, if
applicable.

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3.2.3 Preve tive Mai te a ce Chart
Time Mai te a ce
Clea all tooli g i the followi g areas
 Slides
Daily
 Cylinders
 Check out tooling for signs for of wear.
 Check cutting and termination tools for signs of wear.
 Check condition of slides.
 Check that the air regulator is set to 6 Bar ( 5 psi).
 Ensure all shock absorbers and stops are tight.
Weekly
 Wipe down all tooling in the following areas: slides, cylinders, and carriage rails.
 Carry out Weekly PM.
 Check slide for excessive play (tighten as necessary).
 Check condition of all shock absorbers and stops.
 Check out functionality of all sensors.
 Check for air leaks, loose fittings, damaged airlines, and gauges.
Mo thly
 Check General condition of all tooling.
6 Mo ths  Carry out Monthly Preventative Maintenance.
3.3 Perishable Parts
Customers are responsible for maintaining the The RAST 5.0 Semi-Automatic Terminator Machine.
Perishable parts are those parts that come in contact with the product and will wear out over time. Molex
recommends that all customers keep at least one set of the perishable tool kits in stock at all times. This
will reduce the amount of production down time. These parts are identified in the Parts List below.
Perishable Tooli g List
Order No. Descriptio Qua tity
62300-6101 Housing Cut Blade 1
62300-6102 Termination Tool 1
3.4 Spare Parts
Customers are responsible for maintaining the The RAST 5.0 Semi-Automatic Terminator Machine. Spare
parts are available. Moving and functioning parts can be damaged or wear out over time and will require
replacement. See assembly drawings and parts lists in Section 5 for additional detail.

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Sectio 4
Touch Scree s a d Troubleshooti g

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Touch Scree s
Scree 1
Start Up Scree
This screen appears after the machine has been
powered up.
It is only an information screen.
Scree 2
Ready to Ru Scree
This screen is displayed when the machine is
stopped and there are no fault conditions. It has 2
buttons located on the bottom.
START: This button starts the machine.
MANUAL:Selects manual mode and changes the
screen to the Manual #1 [Screen 30].
Scree 3
Emerge cy Stop Scree
This screen is displayed when the Emergency Stop
button has pressed. It also appears after power up
and after the Safety Guard Open screen, when the
door has been closed. Release the Emergency Stop
button and press the blue reset button on the main
Panel.
Scree 4
Safety Guard Ope Scree
This screen is displayed when the safety guard is
open. Close the guard and press the blue reset
button on the main panel.
Scree 5
Se sor must be Homed Scree
This is displayed after the machine has been reset.
The stepper motor that drives the laser sensor must
be homed after a power loss or Emergency Stop to
ensure it is in the correct position to detect the wires.
Press the HOME button and it will home
automatically. When the sensor reaches the home
position, the Ready to Run screen will be displayed.
Scree 6
Ru i g Scree
This screen is displayed when the machine is
running in automatic mode.

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Parts Made:Displays how many parts have been
made in the current batch.
I sert Wire i to Positio : Displays the position
where the current wire is to be inserted.
STOP:This button stops the automatic mode. The
operator must finish inserting all wires into
the connector and terminate the connector
before the end of cycle is reached.
REDO:This button allows the operator to correct an
error on the existing connector. The mask
tooling will go up, the wire(s) can be removed
and the sensor motor will go to home
position. Screen 9 will be displayed when
this button is pressed.
Scree 7
Waiti g to Stop Scree
This screen is displayed after the stop button has
been pressed and before the current cycle has been
completed.
Parts Made:Displays how many parts have been
made in the current batch.
I sert Wire i to Positio :Displays the position
where the current wire is to be inserted.
REDO:This button allows the operator to correct an
error on the existing housing. The mask
tooling will go up, the wires can be removed
and the sensor motor will go to home
position. Screen 9 will be displayed when
this button is pressed.
Scree 8
Se sor is Homi g Scree
This screen is displayed after the Home Sensor
Button has been pressed on Screen 5. When the
sensor reaches the home position the Ready to Run
Screen will be displayed.
Scree 9
Redo Scree
This screen appears after REDO has been
pressed on either Screen 6 or 7. When all the
wires have been removed, press REDO to return
to Screen 6 or 7.
Scree 10
Co veyor Low Level Fault Scree
This screen is displayed when the connector
conveyor level is low. Join another chain to the
existing chain and press the CLEAR button to
continue.
Scree 13
Housi g Feed ot Back Fault Scree
This screen is displayed when the Housing Feed
Cylinder fails to activate sensor B0.10. Check to
see if the tooling jammed or if something is stopping