TE Connectivity 2161651 Series Reference guide

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TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Customer Manual
409-32023
02 MAR 15 Rev B
SAFETY PRECAUTIONS READ THIS FIRST!..............................................2
1. INTRODUCTION ..................................................................................................................3
1.1. Declaration of Incorporation ........................................................................................3
1.2. Smart Applicator Machine Integration Kit ....................................................................3
1.3. Smart Applicator Precision Controller Integration Kit ..................................................4
1.4. Smart Applicator Direct Integration Kit ........................................................................5
2. RECEIVING INSPECTION AND INSTALLATION ...............................................................5
2.1. Receiving.....................................................................................................................5
2.2. Hardware Installation...................................................................................................5
2.3. Software Installation ..................................................................................................10
2.4. Integration of Hardware and Software.......................................................................20
3. SYSTEM III PRECISION CONTROLLER OPERATION ....................................................21
3.1. Controller Screen, Navigation, and Operation...........................................................22
3.2. Feeder Calibration.....................................................................................................24
3.3. I/O Interface Settings.................................................................................................25
3.4. Terminal Selection.....................................................................................................26
3.5. Run Page Data..........................................................................................................28
3.6. Applicator Page Data ................................................................................................29
3.7. Feeder Data ..............................................................................................................31
3.8. Precision Controller ...................................................................................................31
4. SYSTEM III TERMINAL SERVO FEEDER OPERATION AND CALIBRATION ...............34
4.1. Feeder Operation ......................................................................................................34
4.2. Feeder Calibration.....................................................................................................35
5. TERMINATION QUALITY ..................................................................................................37
6. MAINTENANCE .................................................................................................................40
6.1. Normal Preventive Maintenance and Lubrication......................................................40
6.2. System III Feeder Maintenance ................................................................................40
6.3. Clearing Jammed Terminal Strip...............................................................................41
6.4. Precision Controller Maintenance .............................................................................41
7. RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION....................41
8. REVISION SUMMARY .......................................................................................................41
Smart Applicator Machine Integration Kits 2161651-[ ]
With Precision Controller Integration Kits 2161650-[ ]
and Direct Integration Kits 2161655-[ ]
ORIGINAL INSTRUCTIONS
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SAFETY PRECAUTIONS —AVOID INJURY
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Always insert power plug into a properly grounded
receptacle to avoid electrical shock.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person
familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many
difficulties can be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful
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Figure 1
1. INTRODUCTION
This customer manual covers the system III smart applicator integration kits used with Komax leadmakers with
mci 722 terminators only. See Figure 1.
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.
Reasons for re-issue of this customer manual are provided in Section 8, REVISION SUMMARY.
NOTE
Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
1.1. Declaration of Incorporation
Check Declaration of Incorporation 2217124 prior to putting the machine into operation.
1.2. Smart Applicator Machine Integration Kit
The machine integration kit consists primarily of a connection box and software to integrate the host machine
with precision controller integration kits and/or applicator direct integration kits.
System III Precision Controller
Installed on Komax Leadmaker
with mci 722 Terminator
Komax is a trademark.
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1.3. Smart Applicator Precision Controller Integration Kit
The precision controller integration kit consists primarily of a precision controller, system III terminal servo
feeder, and the hardware that attaches the controller and feeder to the appropriate Komax leadmaker.
The system III terminal servo feed assembly can be used in conjunction with system III applicators and
Ocean applicators to provide the means for feeding terminals into the applicator for crimping. These
applicators can then be used on select leadmakers.
NOTE
Optional feeder calibration block 1901063-1 is recommended.
The system III terminal servo feeder and system III precision controller are shown in Figure 2.
System III Terminal Servo Feeder Specifications
Weight
1.66 kg [3.67 lb]
Length
206 mm [8.1 in.]
Depth
51 mm [2.0 in.]
Height
102 mm [4.0 in.]
Electrical
Supplied by the external power supply or leadmaker base machine
Temperature
4 to 40°C [40 to 104°F]
Relative Humidity
95% maximum non-condensing
Stroke
42 mm [1.66 in.] maximum
Speed
300 mm/sec max [11.8 in./sec max]
Adjustment Increment
0.020 mm [0.0008 in.]
Figure 2
System III Terminal Servo Feeder
System III Precision Controller
USB Software
Update Port
Navigation Keys
(For Controller Screen)
Feeder Control Keys
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1.4. Smart Applicator Direct Integration Kit
The direct integration kit consists of cabling, which connects the smart applicator to the Komax leadmaker. This
kit is typically used when no servo feed applicators are used. This kit allows direct reading of data from
mechanical-feed and/or pneumatic-feed applicators.
The system III precision controller (shown in Figure 2) is responsible for controlling the feeder assembly and
displaying the applicator information through a series of controller navigation and feeder control keys. A
description of the key operation is provided in Paragraph 3.1.
2. RECEIVING INSPECTION AND INSTALLATION
NOTE
Refer to assembly drawing 2161650 or 2161655 located in the print pack. These drawings contain installation information, part
numbers for components and assemblies, application information, and optional components that may be ordered separately
as required. When received, the kit should be checked against the assembly drawing to verify that it is correct for the
application, complete, and not damaged. Contact the Tooling Assistance Center at 1-800-722-1111 with any questions or to
report any problems.
2.1. Receiving
Each kit is thoroughly inspected during and after assembly. Prior to packaging and shipping, a final series of
tests and inspections is made to ensure proper functioning of the kit. The following inspection should be
performed as a safeguard against potential problems generated in transit:
1. In a well-lighted area, carefully uncrate the kit, and inspect each component as it is removed from the
crate.
2. Thoroughly inspect each component for evidence of damage that may have occurred in transit. If any
of the components are damaged, file a claim against the carrier and notify TE immediately.
Keep this manual and all drawings with the kit for the benefit of operation and maintenance personnel.
The controller and feeder should be inspected at regularly scheduled intervals, depending on care, degree of
operator skill, and environmental conditions.
2.2. Hardware Installation
NOTE
Hardware installation consists of installing the machine integration kit, precision controller integration kit(s), and/or direct
integration kit(s).
Installation of Machine Installation Kit
Refer to drawing 2651651 from the machine documentation package. This drawing contains hole cut-outs
and installation instructions for the machine installation kit. This kit must be installed before the hardware
and software can be integrated.
Installation of Machine Integration Kit with Precision Controller Integration Kit onto Komax Leadmaker
1. Remove the side covers (see Figure 3) from the existing terminating unit, and install modified side
cover 2-509805-3. Refer to drawing 2161650. See Figure 4.
NOTE
The side covers wrap around the terminator. Be careful not to damage the communication cable that is connected to the
panel. This cable must be unplugged, then reconnected when installing the modified side cover.
2. Install the adapter plate, feeder holder, cable cradle, and ball lock pins. Refer to Figure 4.
3. Install the system III precision controller onto the side of the terminator.
a. Route the power cable and the communication cable along the side of the terminator and through
the height adjustment mechanism.
b. Route the cable along the back side of the terminator. See Figure 4 and Figure 5.
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Figure 3
Figure 4
Side Cover (Ref)
Ball Lock Pin
Cable Cradle
Adapter Plate
Feeder Holder
Run Power Cable and
Communications Cable
Through Here
Modified Side Cover
System III
Precision Controller
Note: Refer to Drawing
2161650 for additional
photos.
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Figure 5
c. Remove the access cover, and run the cable into the machine. See Figure 5. Run the power cable
into the main electrical box. See Figure 6.
NOTE
Excess cable can be wire-tied and left in the wire way as shown in Figure 5.
d. Connect the power cable to the power block and machine ground as shown in Figure 6. Refer to
schematic 2161898 in documentation package 2161819.
The Ethernet communication cable is connected in the connection box as shown in Figure 7.
Figure 6
Power and Communication Cables
Routed Along Back Side of Terminator
Access Cover Removed
Cable Run Into Machine
Note: Cover Removed for Clarity
Excess Cable in Wire Way
Power Block Located on Right Side
of Main Electrical Box
Ground Connections
on Bottom of
Electrical Cabinet
Power Cable
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Figure 7
4. Route the trigger cable into the back of the terminator, and connect the trigger cable to the air feed
cable. See Figure 8.
5. Remove the air feed cable from the back of the terminator. See Figure 8.
6. Cut and splice both air feed cable and the trigger cable as shown in Figure 8. Connect both cables to
the connector block on the terminator. Make sure to maintain polarity.
Figure 8
Air Feed Cable
Trigger Cable
Splices
Air Feed Cable
and Trigger Cable
Spliced Together
Computer Communications Cable
Connected to USB Port
on Main Computer
Ethernet Communications Cable
2 Kits Shown Installed
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See schematic 2161898 for connection. Ensure that the black wire (-) goes to the (-) and the red wire
(+) goes to the (01). Refer to Figure 9.
Figure 9
Installation of Direct Integration Kit
1. Install the cable cradle. Refer to drawing 2161655. See Figure 10.
NOTE
Make sure to use the existing hardware.
2. Install the phone cable through the machine and into the connection box. See Figure 10. Remove the
machine access panel to aid in fishing cables through the machine.
Figure 10
3. Connect the phone cable to the adapter, and then to the USB hub. See Figure 11.
4. Connect the cable probe to the phone cable using the inline coupler. See Figure 11.
Black Wire
Red Wire
Cable Cradle
Fish Cable Through Machine
Access Panel Removed
Phone Cable
Connection Box Supplied with
Machine Integration Kit
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Figure 11
2.3. Software Installation
1. Verify that the TopWin software version on the machine is:
12.4 or newer for Komax leadmaker A355, A355S, A356
13.2 or newer for Komax leadmaker G263
13.3 or newer for Komax leadmaker A488S
14.1 or newer for Komax leadmaker A477, A488
14.2 or newer for Komax leadmaker Z633
2. Install the TE server application on the machine by copying the file
“ApplicatorDataSetup_Version_5.0.6.exe” (or newer) to the machine.
When this file is executed, it will install the TE server application and necessary utilities.
During the installation:
—the installer must accept the software license agreement,
—the software license agreement must be accepted by the operator,
—and the installer must have administrator’s rights to install the programs.
During installation, the following will happen:
a. ErrorLogService will install,
b. DNSDiscoverService will install,
c. TE InterfaceII dll will install,
d. Postgres database will install and build the database,
e. Shortcuts will be created in the START menu in "Start->All Programs->ApplicatorData", and
f. A program will enable all the ports necessary in the firewall to allow the TEServerApp and utilities
to operate properly.
USB Hub
Adapter
Phone Cable
2 Kits Shown
Installed
Back Right Side
of Terminator
Cable Probe
Inline Coupler
TopWin is a trademark.
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