TE Connectivity FFC Base Machine Mark II 4-528000-7 User manual

OPERATING INSTRUCTIONS
FFC BASE MACHINE MARK II
TE P/N 4-528000-7
Document number: 412-94349-3
TE Connectivity (TE) PN: 8-744017-2
Language: en (translation of the German original version)

FFC BASE MACHINE MARK II
TE P/N 4-528000-7
TE Connectivity Germany GmbH
a TE Connectivity Ltd. Company
Ampèrestr. 12–14
64625 Bensheim
Germany
Phone [phone]
Fax [phone]
www.te.com
Certified in accordance with ISO 14001 and ISO/TS 16949:2002
© 2016 TE Connectivity Gesellschaften. All Rights Reserved.
General information
The information provided is for the purpose of product descriptions only. Users must
conduct their own assessments and tests. It should be noted that our products are
subject to natural wear and ageing processes.
The front page shows a sample configuration. The supplied product may vary from
that shown.
The original operating instructions were written in German.

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Table of contents
1Revisions.........................................................................................................5
1.1 Revision history .......................................................................................................................5
2Introduction..................................................................................................... 6
2.1 About these operating instructions ..........................................................................................6
2.2 Signs and symbols used in this document ..............................................................................6
2.2.1 Instructions...............................................................................................................................6
2.2.2 Notes........................................................................................................................................7
2.2.3 Safety instructions ...................................................................................................................7
2.3 Abbreviations...........................................................................................................................7
3General safety instructions............................................................................8
3.1 Intended use............................................................................................................................8
3.1.1 Interchangeable tools ..............................................................................................................8
3.1.2 Accessories..............................................................................................................................9
3.2 Improper use............................................................................................................................9
3.3 Foreseeable misuse ................................................................................................................9
3.4 Warnings..................................................................................................................................9
3.4.1 Safety signs (type-specific)....................................................................................................11
3.4.2 Mandatory safety signs..........................................................................................................11
3.4.3 Prohibition signs ....................................................................................................................12
3.5 The operator's duties.............................................................................................................12
3.6 Qualification of personnel......................................................................................................13
3.7 Safety devices .......................................................................................................................14
3.7.1 Emergency stop switches......................................................................................................14
3.7.2 Protective cover.....................................................................................................................14
3.8 Work areas/Danger zone.......................................................................................................15
3.9 Safety measures....................................................................................................................16
3.9.1 General..................................................................................................................................16
3.9.2 Electrical safety......................................................................................................................16
3.9.3 Safety measures for commissioning......................................................................................17
3.9.4 Safety measures for transport and installation......................................................................17
3.9.5 Safety measures during operation.........................................................................................17
3.9.6 Safety measures for upkeep, maintenance and repair..........................................................18
3.9.7 Safety measures for troubleshooting.....................................................................................18
3.9.8 Safety measures for decommissioning..................................................................................18
4Technical data............................................................................................... 19
4.1.1 Rating plate............................................................................................................................19
4.1.2 Machine data .........................................................................................................................19
4.1.3 Product/performance data.....................................................................................................20
4.1.4 Operating/ambient conditions................................................................................................20

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4.1.5 Connection data.....................................................................................................................20
5Functional description.................................................................................. 21
6Layout............................................................................................................ 22
6.1 Layout: front view..................................................................................................................22
6.2 Layout: rear view ...................................................................................................................23
6.3 Structure, side view ...............................................................................................................24
6.4 Control and indicating elements ............................................................................................25
6.4.1 FFC crimping machine control panel.....................................................................................25
6.4.2 Operating modes ...................................................................................................................26
6.5 Control ...................................................................................................................................26
6.5.1 Programmable controller (PLC).............................................................................................26
7FFC crimping machine control display....................................................... 27
7.1 User levels.............................................................................................................................27
7.2 Automatic mode.....................................................................................................................28
7.2.1 Loading a program.................................................................................................................29
7.2.2Production..............................................................................................................................30
7.3 Setup mode............................................................................................................................31
7.3.1 Cylinder..................................................................................................................................32
7.3.2 Crimping press.......................................................................................................................33
7.3.3 Motor Table............................................................................................................................34
7.3.4 Setup......................................................................................................................................35
7.3.5 Program.................................................................................................................................39
7.4 Login/Logout..........................................................................................................................41
7.5 Error Messages .....................................................................................................................42
8Delivery.......................................................................................................... 43
8.1 Internal transport (before unpacking) ....................................................................................43
8.1.1 Reasonable loads..................................................................................................................43
8.2 Receipt and unpacking of goods ...........................................................................................44
8.2.1 Unpacking the machine.........................................................................................................44
8.2.2 Checking consignment ..........................................................................................................44
8.3 Transport instructions (after unpacking)................................................................................45
8.4 Storage, temporary storage...................................................................................................46
9Commissioning............................................................................................. 47
9.1 Installation/Assembly.............................................................................................................47
9.1.1 FFC crimping machine...........................................................................................................47
9.1.2 Foot switch.............................................................................................................................47
9.1.3 Routing of cables and hoses .................................................................................................48
9.2 Installation/Connection ..........................................................................................................48
9.2.1 Electrical ................................................................................................................................49
9.2.2 Compressed air .....................................................................................................................49

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9.3 Preparation/Commissioning...................................................................................................49
9.3.1 Language selection................................................................................................................49
9.3.2 Program creation ...................................................................................................................50
9.4 Inserting the terminal belt ......................................................................................................50
9.5 Tool change...........................................................................................................................53
9.5.1 Tool installation......................................................................................................................54
9.5.2Tool removal..........................................................................................................................56
9.6 Setting the printed conductor detection.................................................................................56
9.6.1 Adjusting the sensor position.................................................................................................57
9.7 Setting the terminal feed........................................................................................................57
9.7.1 Setting the terminal feed with pneumatic feed.......................................................................58
9.7.2 Setting the terminal feed with mechanical feed.....................................................................58
9.8 Setting the crimp height.........................................................................................................59
9.8.1 Adjusting the crimp height on the applicator..........................................................................59
9.8.2 Setting the crimp height on the machine...............................................................................59
9.9 Changing the foil guide..........................................................................................................60
10 Operation/Use ............................................................................................... 62
10.1 Preconditions.........................................................................................................................62
10.2 Switching on and off ..............................................................................................................62
10.3 Production mode/Normal mode.............................................................................................63
10.3.1 Crimping program selection...................................................................................................63
10.3.2 Production sequence.............................................................................................................63
11 Troubleshooting............................................................................................ 64
11.1 General troubleshooting information .....................................................................................64
11.2 Overview of error reports and how to handle them ...............................................................65
11.3 Faults and remedies ..............................................................................................................66
12 Maintenance .................................................................................................. 67
12.1 Maintenance overview (maintenance list) .............................................................................67
12.2 Maintenance activities ...........................................................................................................67
12.2.1 Visual inspection....................................................................................................................68
12.2.2 Clean the machine.................................................................................................................68
12.2.3 Lubricating the tool lifting unit................................................................................................69
12.2.4 Lubricate tool guide pins........................................................................................................69
13 Decommissioning......................................................................................... 71
13.1 Taking the machine out of service.........................................................................................71
13.2 Storage ..................................................................................................................................71
14 Disposal......................................................................................................... 72
15 Drawings, parts lists, circuit diagrams ....................................................... 73

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16 Customer Service Europe, Middle East, Africa (EMEA)............................. 74

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1 Revisions
1.1 Revision history
Rev.
Date
Description
Name
A
03/07/2018
First version
P. C. Knapp
B
15/08/2018
Update HMI images
P. C. Knapp
B1
11/09/2018
Update Links
P. C. Knapp
Table 1: Revision history

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2 Introduction
2.1 About these operating instructions
These operating instructions describe the use and operation of the FFC Base Machine Mark II
4-528000-7, hereafter referred to as the FFC crimping machine, as well as the necessary
maintenance measures.
All persons using the FFC crimping machine must therefore be familiar with these operating in-
structions and follow the instructions contained herein.
These operating instructions must be available at the FFC crimping machine at all times.
The machine owner/user is obliged to supplement these operating instructions with instructions
in line with existing national regulations for the prevention of accidents and environmental pro-
tection.
These operating instructions apply to the following TE Connectivity FFC crimping machine(s):
4-528000-7
Additional documents
The following documents must be observed in addition to these operating instructions:
Keyence LV-N10 operating instructions
Warranty claims, liability
TE Connectivity disclaims all liability for any loss or damage arising from failure to observe the
instructions provided on the hand tool or in the operating instructions.
The manufacturer is not liable for any damage attributed to changes or modifications to the
bench top machine not mentioned in these operating instructions.
Service
For further information and technical support, please contact TE Connectivity Customer Service.
For addresses, see Section 16.
2.2 Signs and symbols used in this document
The signs and symbols shown in this section are used in these operating instructions.
2.2.1 Instructions
Instructions are marked as follows
For action steps
✓For action results

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2.2.2 Notes
General note on operation or use.
2.2.3 Safety instructions
Special safety instructions are provided where necessary. See Section 3.
2.3 Abbreviations
Abbrevia-
tion
Meaning
FFC
Flexible Flat Cable
FPC
Flexible Printed Circuits
Table 2: Abbreviations used

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3 General safety instructions
The machine has been manufactured in line with current industry standards and recognised
safety rules.
Nevertheless, there is a risk of personal injury and material damage if the following general
safety instructions and the warnings preceding the instructions in these operating instructions
are not observed.
3.1 Intended use
The FFC crimping machine for FFC terminals with P/N 4-528000-7 is used to process contact
parts for the FFC-ACTION PIN, FFC-CARD EDGE, FFC-Junior Timer, FFC-Solder Peg, FFC-
MODU.050, FFC-MODU.100, FFC-MQS, FFC-NanoMQS and FFC-Socket series.
The parts specified in Section 3.1.1 can be used for this purpose
Operational environment
The machine must only be used in a dry, dust-free environment.
The machine must not be used in gaseous environments.
3.1.1 Interchangeable tools
The FFC crimping machine can be provided with intermountable tools for crimping different
products.
The FFC crimping machine is normally supplied with one specific tool.
If additional tools are used, observe the crimping specifications for the respective
tools. These contain specific information on the use of these tools.
Read this information before using other tools with the FFC crimping machine.
Tools
Tool
PN
Application
FFC-ACTION PIN
PN 5-528441-6
TE Spec. 114-18210-0
TE Spec. 114-16015
FFC-CARD EDGE
PN 4-528441-9
TE Spec. 114-16015
FFC-Junior Timer
PN 3-528441-7
TE Spec. 114-18409-1
FFC-Solder Peg
PN 5-528441-7
TE Spec. 114-16015
FFC-MODU.050
PN 3-528441-9
TE Spec. 114-16008
FFC-MODU.100
PN 5-528441-5
TE Spec. 114-16015
FFC-MQS
PN 5-528441-3
TE Spec. 114-18287-1
FFC-NanoMQS
PN 3-528508-2
PN 3-528508-7
TE Spec. 114-94383
FFC-Socket
PN 528508-3
TE Spec. 114-16015
Table 3: Tools

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No other tools are included in the scope of delivery. These can be ordered sepa-
rately. Information on other tools is available from the Customer Support Centre,
see Section 16.
3.1.2 Accessories
The FFC crimping machine can be equipped with accessories.
The FFC crimping machine is delivered without accessories.
If an accessory part is required, observe the processing specifications for the corresponding ac-
cessory. These give specific information regarding the accessory's use. Read this information
before using an accessory with the FFC crimping machine.
3.2 Improper use
Applications other than those mentioned in the "Intended use" section or those described in
these operating instructions or any further application constitute improper use. Further infor-
mation can be found in Section 3.1 Intended use page 8.
TE shall not be held liable for any damage or loss resulting from these. The risk lies solely with
the user or operator.
Any arbitrary modifications made to the FFC crimping machine will lead to loss of warranty.
3.3 Foreseeable misuse
The FFC crimping machine 4-528000-7 must only be used for the purpose described above.
Use for any other purpose is considered improper and is deemed to be misuse. Further infor-
mation can be found in Section 3.1 Intended use page 8.
This applies in particular to:
inadmissible tool-product combinations
inadmissible tool kits
crimping of live wires
3.4 Warnings
The signs and symbols set out in this section are used in these operating instructions.
Hazard
HAZARD!
Type of hazard
Cause
Measures for averting hazards
"Hazard" indicates an imminently dangerous situation which, if not averted, can result in fatality
or serious (irreversible) injuries.

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Warning
WARNING!
Type of hazard
Cause
Measures for averting hazards
"Warning" indicates a potentially dangerous situation which, if not averted, can result in fatality
or serious (irreversible) injuries.
Caution
CAUTION!
Type of hazard
Cause
Measures for averting hazards
"Caution" indicates a potentially dangerous situation which, if not averted, can result in minor or
less serious (reversible) injuries.
Attention
ATTENTION!
Type of hazard
Cause
Measures for averting hazards
"Attention" draws attention to information or recommendations which may refer directly or indi-
rectly to the safety of persons or material damage.

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3.4.1 Safety signs (type-specific)
The following safety signs are used in these operating instructions and the area surrounding the
machine in order to warn the operator of hazards:
General warning
This warning sign accompanies specific activities subject to various hazards.
Hand injuries warning
This warning sign accompanies specific activities where there is a risk of hands
being trapped, entangled or injured in other ways.
Danger of electricity, electric shock
This warning sign accompanies specific activities where there is a risk of electric
shock, possibly with fatal consequences.
Suspended load warning
This warning sign accompanies activities where there is a risk of falling objects.
Hot surface warning
This warning sign accompanies activities where there is a hazard due to hot sur-
faces.
3.4.2 Mandatory safety signs
The following mandatory safety signs are used in these operating instructions and the area sur-
rounding the machine in order to advise the user to wear personal protective equipment.
Eye protection must be worn
Eye protection must be worn when using tools, machines and apparatus in normal
use
Ear protectors must be worn
Ear protectors must be worn when entering specifically designated areas or oper-
ating machines and apparatus. There is otherwise a risk of reduced hearing sensi-
tivity (reversible hearing loss after an extended period) and deafness following pro-
longed exposure (irreversible hearing loss).
See the operating instructions
The described object (machine) may be used only after the user has read the op-
erating instructions.
Safety gloves must be worn
If safety gloves must be worn due to a risk of injury, this must be indicated.
The use of safety gloves must be regulated in the operating instructions, because
there are certain types work for which safety gloves must not be worn.

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Remove plug from mains
The mains plug must be unplugged before opening the housing.
3.4.3 Prohibition signs
The following prohibition signs are used in these operating instructions and the area surround-
ing the machine in order to warn the operator of hazards:
Removal of safety devices prohibited
This prohibition sign is used when it is forbidden to remove safety devices.
3.5 The operator's duties
The operator is the owner of the machine and, therefore, bears the operator's responsibility and
is subject to industrial safety regulations (BetrSichV). The operator is obliged to comply with the
laws, regulations, directives and standards stipulated therein. This results in certain legal, cor-
porate and personal obligations for the operator such as:
The operator undertakes legal responsibility for the consequences of any culpable breach of
duty.
The operator is responsible for the administration and keeping secret of passwords.
The operator must ensure that the work area around the machine is kept clear. A clean and tidy
working area produces safety.
The operator must make sure that inspection and maintenance requirements are adhered to.
The operator must make sure that the personnel are informed before special or maintenance
procedures are carried out.
The operator must allow the system to be tested periodically by qualified health and safety pro-
fessionals according to locally or regionally established regulations. The results must be rec-
orded in an inspection report.
The operator is also required to provide supplements to the operating manual in the form of ad-
ditional operating instructions which take into account any local regulations that are in force,
such as for:
–Provisions for the prevention of accidents
–Waste disposal legislation
–Protective equipment and maintenance
–Disposal
–Environmental Protection
–Instructions for emergencies
–Advice for handling hazardous materials

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The operator must ensure that the following tests are carried out:
–Testing of the machine for operating safety
–Functional tests of safety devices
–All tests dictated by the maintenance plan
The operator must ensure that a copy of the operating instructions is kept to hand at the ma-
chine at all times.
The operator must ensure that the machine is readily accessible.
The operator must ensure that no unauthorised persons are allowed access.
The operator must ensure that the personnel have read, understood and shall follow the operat-
ing instructions.
The operator must ensure that all personnel working with the machine are trained in accordance
with their tasks.
The operator must ensure that all safety information, safety rules, and safety instructions and
safety information are adhered to.
The operator must ensure that safeguards and codes of conduct have been stipulated with the
responsible persons.
The operator must set down clear responsibilities for specific activities in operating the machine.
For activities that have a particular bearing on safety, specific duties must be clearly assigned.
The operator must enforce the wearing of protective clothing (e.g. protective gloves) by the per-
sonnel, in so far as the personnel's health requires it.
The operator is responsible for handling the products to be processed.
The operator is responsible for the application of additional equipment and utility services. The
corresponding safety regulations must be adhered to
3.6 Qualification of personnel
The machine must be operated and maintained only by fully trained and qualified personnel.
The operator is responsible for ensuring that every person working with the machine has been
familiarised with the contents of these operating instructions.
The operator is also responsible for the training of operating personnel, which must include the
following:
Application
Hazards
Safety regulations
Function
Operation
To ensure that the instruction has been understood, training must be provided in the language
of operating personnel.

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Necessary qualification of personnel
Assembly start-
up instruction
Qualified technical personnel who, in addition to German and English,
also speak the language of operating personnel
Operation
Qualified persons trained by technically skilled persons.
Maintenance ser-
vicing
Technically skilled persons who speak German or English.
Table 4: Qualification of personnel
3.7 Safety devices
The machine's protective and safety devices serve for the protection of operating and mainte-
nance personnel (users) and others against the majority of hazards that can occur during use
(operation) of the machine.
However, certain safety precautions must be taken by operators, maintenance and repair per-
sonnel to prevent personal injury and damage to the machine.
The 4-528000-7 machine is equipped with the following protective and safety devices:
An emergency stop switch
A movable protective cover for protection against accidental access
A safety micro-switch on the front protective cover
A solid cover for the electrical parts
A safety valve for compressed air
3.7.1 Emergency stop switches
The machine has emergency stop switches for switching off the machine in dangerous situa-
tions or emergencies.
Emergency stop switches are located:
On the front of the machine
When the emergency stop switch is pressed, all movements are stopped.
3.7.2 Protective cover
A transparent protective cover, which must be pushed into the working position after the tool
has been mounted, is provided to protect against unintentional access to the danger zone.

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Figure 1: Protective cover
3.8 Work areas/Danger zone
The operator must stand only in the operator area marked with cross-hatching (1).
Figure 2: Work areas/Danger zone

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All other areas of the machine must be regarded as danger zones.
No.
Danger zone
Endangered
person
Type of danger
1
Foil table area
Operator
Risk of crushing if the machine is
not properly installed
2
Work area around the machine
Operator
Setup
Tripping hazard if cables are not
laid properly
3
Open machine
Setup
Direct/indirect contact with the
machine's moving parts
Cut hazard
Crushing hazard
Table 5: Danger zones
3.9 Safety measures
3.9.1 General
The machine must be used only for the intended purpose. The respective application specifica-
tion must be observed.
The machine must be used only by trained and authorised personnel.
The responsibilities of personnel for operation, setup, maintenance and repair must be clearly
defined and observed by the owner/operator of the machine.
3.9.2 Electrical safety
The machine's electrical connections must correspond to local standards and regulations.
Touching any component under electrical tension can lead to severe electric shocks, burn inju-
ries, paralyses, cardiac arrest and death.
Use the machine only when all covers or panels are securely in place. If the machine is used
without covers, potentially hazardous voltages will be exposed.
The machine's power feeding has double pole fusing (line & neutral) and must be connected to
an earthed power supply.
Use only specified fuse types as ratings.
The machine is designed for operation from a 230 V 50 Hz power supply and is supplied with a
2 metre-long power cable.
Do not conduct a high voltage test. This could damage the electrical components of the ma-
chine.
The value of 250 V DC must not be exceeded during insulation resistance tests; otherwise there
is the risk of damage to the machine's protection circuits.

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3.9.3 Safety measures for commissioning
The machine must be set up and operated only in a technically perfect condition with aware-
ness of safety aspects and potential dangers.
The proper mounting and functioning of all safety devices, particularly protective covers, must
be ensured before each use.
Protective covers may only be removed when the machine stationary and tools are discon-
nected from the power supply.
Housings and covers in particular must be removed only by qualified personnel.
3.9.4 Safety measures for transport and installation
The FFC crimping machine is delivered in a wooden crate or firmly secured on a pallet. In view
of the limited weight (approx. 120 kg), there are no particular problems in handling the machine.
Persons working on the machine must wear protective gloves and safety shoes.
Lift the machine only with suitable aids (lift truck, pallet truck, and forklift).
Lift the crate or pallet off the floor only as much as necessary to ensure easy handling.
Use the suspension eye provided for lifting the machine onto the workbench. The suspension
eye is located above the machine's electrical control panel. The strap must be firmly secured to
the suspension eye and of the correct dimensions to withstand a weight of more than 500 kg.
Ensure that no persons are in the danger zone.
Observe the on-site safety regulations as well as those described herein.
3.9.5 Safety measures during operation
The machine must be used only when it is in technically perfect condition and with awareness of
safety aspects and potential dangers.
If the machine is considered to be no longer safe to use, it must be rendered inoperative and
locked to prevent it from being unintentionally switched on again.
Never crimp live wires
The machine must be operated only with mounted tools.
The machine must be operated only when it is in a complete and functional condition.
Do not wear loose clothing or jewellery; long hair must be tied back to avoid being caught in
moving machine components.
Work with care!
In the event that defects are detected in the machine, work must be interrupted and the error
remedied before work with the machine is continued.
The machine may be operated by only one person at any one time.
The machine may be used only by trained personnel.

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3.9.6 Safety measures for upkeep, maintenance and repair
When carrying out upkeep work, maintenance or repairs, always follow the instructions in these
operating instructions or consult TE if you require advice. A record should be kept of the mainte-
nance and servicing of the machine.
Turn off the entire energy supply (electricity, compressed air, etc.) before all cleaning, mainte-
nance or repair work.
The energy supply should be protected against accidental switch-on (for example, the main
switch should be padlocked).
Upkeep, maintenance and repair work must be carried out only by technicians qualified in the
relevant area.
Machine and system components subject to maintenance and servicing must be disconnected
from the power supply unless stated otherwise in these operating instructions. The discon-
nected components must initially be checked for the absence of power, earthed and short-cir-
cuited and adjacent live parts insulated.
The machine's electrical equipment must be regularly tested. Defects, such as loose connec-
tions or scorched cables, must be remedied immediately.
If work must be carried out on live parts, a second person must be present to operate the Emer-
gency Stop switch or main switch or isolate the machine from the supply in an emergency if
necessary. Only electrically insulated tools may be used!
3.9.7 Safety measures for troubleshooting
Error rectification must be carried out only by technicians qualified in the relevant area.
Switch the entire power supply (electricity, compressed air, etc.) off for all troubleshooting.
The energy supply should be protected against accidental switch-on (for example, the main
switch should be padlocked).
3.9.8 Safety measures for decommissioning
Switch the entire power supply (electricity, compressed air, etc.) off for all decommissioning.
The disconnected components must initially be checked for absence of power, then earthed and
short-circuited. The compressed air system must be vented.
Lift the machine only with suitable aids (lift truck, pallet truck, and forklift).
Use the suspension eye provided for lifting the machine from the workbench. The suspension
eye is located above the machine's electrical control panel. The strap must be firmly secured to
the suspension eye and of the correct dimensions to withstand a weight of more than 500 kg.
Ensure that no persons are in the danger zone.
Observe the on-site safety regulations as well as those described herein.