Tyco Electronics RAYCHEM WAFFLE IRON II Operating instructions

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 1 of 16
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RAYCHEM
INTERCONNECTION SYSTEMS DIVISION
ENGINEERING STANDARD
ES 61402
OPERATING AND MAINTENANCE MANUAL
WAFFLE IRON II HEATING TOOL

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 2 of 16
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OPERATING AND MAINTENANCE MANUAL
WAFFLE IRON II HEATING TOOL

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 3 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
WARNING The Waffle Iron II has exposed hot surfaces.
WARNING To prevent danger of electric shock, do not remove covers. There are no user-serviceable
parts inside.
WARNING When using release agent in pressurized containers, read and observe all manufacturer's
precautions, warnings, and instructions.
WARNING Do not touch infrared lamps. They may be hot and can cause burns.
WARNING In keeping with good industrial hygienic practice, adequate ventilation must be
maintained whenever plastic materials are heated.
CONTENTS
SECTION SUBJECT
1. Description
1.1 General
1.2 Function
1.3 Specifications
2. Preparation For Use
2.1 Power connection
2.2 Platen installation
3. Operating Instructions
3.1 Turn-on procedure
3.2 Control settings
3.3 Termination procedure
4. Calibration Verification Test
4.1 Objective
4.2 Tools required
4.3 Procedure
5. Maintenance
5.1 Cleaning
5.2 Preventing parts from
sticking
5.3 Upper heat sink hinge
adjustment
5.4 Troubleshooting
5.5 Replacement parts list

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 4 of 16
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1. Description
1.1 General
Raychem's Waffle Iron II is a portable heating tool for terminating components of Raychem's
Integrated Interconnection System (I2S). The Waffle Iron II contains a microprocessor-based
controller which provides heating time and temperature adjustment, fault and error
monitoring, and display of operational status.
Standard product applications include: CTM splice modules for flat conductor cable, CTM
transitions for splicing flat conductor cable to round wire, MTC50 and MTC100 connector
wafers for flat conductor cable, and SEM connector wafers for flat conductor cable.
The part to be terminated is fixtured between two platens which hold the part in place and
apply heat and pressure during the termination cycle.
Each platen is heated by an infrared quartz lamp. To accommodate different interconnection
components, different platens are used, which snap in and out of their mounting fixtures. The
upper platen and lamp are mounted in a hinged heat sink which opens for loading and
unloading.
Controls include a power switch, a heating time control, a temperature control, and a button
to initiate the heating cycle. Four indicator lights provide the operator with operational status
information.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 5 of 16
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1.2 Function
When the Waffle Iron II power is switched on, the controller undergoes a self test. If the
circuits are functioning properly the green READY/ERROR light will illuminate, and the
unit is ready for use. A heating cycle is initiated by pressing the START button, which turns
on the infrared lamps and the HEATING indicator light.
When the platens reach the set-point temperature, the timer starts and the controller regulates
the platen temperature for the time period selected. After the timed heating period the heat
lamps and HEATING indicator light go out, the COOLING indicator light illuminates, and
the blower comes on to cool the platens. The cooling cycle lasts 3 minutes or until the platens
cool to 125°F, whichever occurs first. At the end of the cooling period the green
READY/ERROR indicator light illuminates, and the terminated component can be removed.
The green READY/ERROR indicator light will flash continuously if the operator makes one
of the following errors:
oAttempting to start a heating cycle without first opening the upper heat sink to
remove completed termination.
oFailing to close upper heat sink before starting a cycle.
oOpening upper heat sink during heating cycle.
Flashing red FAULT light indicates a hardware failure requiring repair by a Raychem field
service representative.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 6 of 16
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1.3 Specifications
Power Requirements Model CE-1404200 (120 V) 100-120 VAC,
50-60 Hz, 20 A
Model CE-1404300 (240 V) 200-240 VAC,
50-60 Hz, 10 A
Overall Cycle Time 3-4 Minutes
Temperature Per TEMP control dial: Setting "0" through "9"
Set-Point Range
Time at Temperature Per TIME control dial: Setting "0" through "9"
Setting Range
Product Capacity CTM splices for flat conductor cable
CTM transitions for flat cable to round wire
MTC50 and MTC100 connector wafers for flat conductor cable
SEM connector wafers

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 7 of 16
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2. Preparation For Use
2.1 Power Connection
Connect the Waffle Iron II to a grounded 50 or 60 Hz power source of the current capability
and voltage specified on the back of the heating tool.
2.2 Platen Installation
Step 1
Select the correct platen set as called out in the product installation instructions.
Step 2
Before installation or after cleaning, spray or wipe platens with light coat of release agent,
such as Miller-Stephenson MS-122* or Axel MoldWiz**.
oCoat only the side of the platen that comes into contact with the part being
terminated.
Step 3
Make sure that the power is turned off.
Step 4
Unlatch and open the upper heat sink by pushing it down and releasing it.
*Miller-Stephenson Chemical Co., Inc.
Danbury, Connecticut 06810
** Axel Plastics Research Laboratories, Inc.
41-14 27th. St., Long Island City, NY 11101
WARNING
When using release agent in pressurized containers,
Read and observe all manufacturer’s precautions, warnings,
and instructions

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 8 of 16
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Step 5
Remove/install platens as required.
oPlatens are locked into heat sinks by a spring-loaded retainer.
oIdentification markings face the operator.
oTop platen has one keying slot.
oBottom platen has two keying slots.
WARNING
Do NOT touch infrared lamps. They may still be
hot and can cause burns.
Step 6
Close and latch the upper heat sink.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 9 of 16
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3. Operating Instructions
3.1 Turn-On Procedure
Step I
Make sure that set-up is completed as detailed in section 2.
Step 2
Turn on the power (ON-OFF) switch.
oThe green READY/ERROR light will illuminate steadily when the self test is
completed and the tool is ready for operation.
oIf the green READY/ERROR light is flashing, the upper heat sink is probably not
closed and latched.
oIf the red FAULT light is flashing, a hardware failure is indicated. Turn the unit off
and contact a Raychem field service representative.
Step 3
Press the START button to initiate a heating cycle to warm the tool and verify its operation.
oThe TEMP and TIME controls can be at any setting for this cycle.
oThe green READY/ERROR light should go out and the yellow HEATING light
should illuminate. Light from the heat lamps should be visible under the upper heat
sink, and the heat sink should become warm.
oWithin one minute the yellow HEATING light should go out and
the yellow COOLING light should illuminate. The light from
the heat lamps should go out and the cooling
fan should come on.
oWithin three minutes the yellow COOLING light should go out
and the green READY/ERROR light should illuminate.
The fan should go off at this time.
3.2 Control Settings
Set the TEMP and TIME controls as specified for the particular component being terminated.
oRefer to the appropriate product installation instructions for control settings.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 10 of 16
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3.3 Termination Procedure
WARNING
In keeping with good industrial hygienic practice, adequate ventilation must be
maintained whenever plastic materials are heated.
Step 1
Make sure that the set-up is completed (section 2), the tool is turned on and warmed up (para. 3.1),
and the TEMP and TIME controls are set (para. 3.2).
Step 2
Open the upper heat sink and the cable clamps.
Step 3
Load the assembly to be terminated onto the lower platen of the heating tool.
oPosition CTMs so that the top surface faces upward and the CTM is centered in the
platen.
oPosition MTC and SEM connector wafers against the stop in the platen, with the
contact numbers facing upward. The cable or wires should extend to the operator's
right.
oPosition round wires through the platen comb and close the clamp.
Step 4
Line up the edges of the cable (FCC) with the cable guide lines in the top surface of the heating
tool, and close the clamp(s) on the cable.
Step 5
Inspect to make sure that the cable or wires are fully inserted and properly positioned on top of the
solder terminals. Reposition cable or wires if necessary.
Step 6
Close and latch the upper heat sink.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 11 of 16
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Step 7
Press the START button to initiate the termination cycle.
oThe upper heat sink must be latched and the green READY/ERROR light must be on
before the termination cycle can be started.
oThe yellow HEATING light will illuminate when the START button is pressed.
oDo not open the upper heat sink during the heating cycle. The platens may be hot
enough to cause burns, and the termination may have to be rejected.
oIf the upper heat sink is inadvertently opened, the green READY/ERROR light will
continue to flash until the heat sink is closed and the START button is pressed.
Step 8
Allow the termination cycle to continue until the green READY/ERROR light comes on.
oAfter the heating portion of the cycle is completed, the yellow HEATING light will
go out and the yellow COOLING light and the cooling fan will come on.
oThe cooling period lasts 3 minutes or until the platens cool to approximately 125°F,
whichever occurs first.
Step 9
Open the upper heat sink and the cable clamps, and remove the completed termination.
WARNING
Do NOT touch the platens. They are hot and
could cause burns.
oThe upper heat sink must be opened and closed before another cycle can be initiated.
oNo damage will occur to the terminated part if it is left in the Waffle Iron II after the
termination cycle is completed.
Step 10
Inspect the completed termination in accordance with the appropriate product application
document.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 12 of 16
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4.0 Calibration Verification Test
4.1 Objective
This procedure is performed to verify whether the Waffle Iron II control system is operating
correctly and the heating temperatures are within the specified ranges. Results of this test will
determine if the heating tool can be used, or if it must be recalibrated by an authorized
Raychem representative. No adjustments are to be performed.
4.2 Tools Required
oTest platen:
a. For early model Waffle Iron II's without thermocouple connection on back, the
CE-1406800 calibration platen is required.
b. For late model Waffle Iron II's with thermocouple connection on back of unit, any
platen set in good condition or a CE-1406800 calibration platen can be used.
oDigital thermometer with peak hold feature, or strip chart recorder; must be
compatible with type K thermocouple.
oStop watch
4.4 Test Procedure
1. Install test platen:
oFor early model Waffle Iron II's without thermocouple connection on back of unit,
remove the production platen and install the CE-1406800 calibration platen. The
calibration platen locks into the lower heat sink the same as a production platen.
oFor late models with thermocouple connection, install the normal production platen
set in the Waffle Iron II. (The CE-1406800 calibration platen may also be used.)
2. Close and latch the upper heat sink.
3. Connect the temperature recording device to the thermocouple.
oIf the Waffle Iron II is an early model without a thermocouple connection, connect
the thermocouple lead of the CE-1406800 calibration platen into the temperature
recording device.
oIf the Waffle Iron II is a late model and has a thermocouple connection, connect the
thermocouple lead (supplied) between the temperature recording device and the
thermocouple connection on the back of the unit.
4. Turn the Waffle Iron II on.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 13 of 16
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5. Set the TEMP dial to 0 and the TIME dial to 5.
6. Run two warm-up heating cycles.
oEither open the upper heat sink or turn the POWER switch off and on to reset the
heating tool between heating cycles.
7. Perform the test cycle once for each TEMP/TIME setting in the table below. The test
cycle is as follows:
a. Set the TEMP/TIME controls to the appropriate numbers.
b. Simultaneously push the START button and start the stopwatch and temperature
recording device.
c. Monitor or record the temperature throughout the 10-second window starting at 25
seconds and ending at 35 seconds.
8. Compare the peak temperatures measured in the time window to the requirements in the
temperature table below. The maximum temperature reached during the 10-second
window must fall within the applicable range from the temperature table.
IMPORTANT: A numerical correction factor must normally be added to or subtracted from
the measured temperatures:
a. For early units, apply the correction factor located on the tag attached to the
CE-1406800 calibration platen.
b. For late model units, always apply the correction factor located above the
thermocouple connection on the back. (If using the CE-1406800 calibration platen
with late model units, disregard the correction factor on the tag.)
If the peak temperature readings fall outside the limits specified in the temperature table, the
heating tool should be removed from service, and the Raychem Field Service Representative
contacted to arrange for repair or recalibration.
TEMPERATURE TABLE
WAFFLE IRON II
CONTROL SETTING
TEMPERATURE REQUIREMENT, °F
(RANGE OF MAXIMUM TEMPERATURE TO BE
REACHED DURING 10-SECOND WINDOW
TEMP TIME
0 5 340 - 380
1 5 355 - 395
2 5 370 - 410

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 14 of 16
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5.0 Maintenance
WARNING
Disconnect the heating tool from its power source before
performing maintenance.
5.1 Cleaning
5.1.1 Keep the platens clean and free from residues such as melted sealing material. Remove and
clean the platens daily or as often as necessary, using a clean tissue moistened with
trichloroethane.
oDo not immerse platens, pour solvent on platens, or clean platens without removing
them from the heating tool.
5.1.2 Carefully remove any debris that might fall into the reflector areas when platens are
removed.
5.1.3 Clean reflectors and lamps if they become dirty, using a soft cloth or tissue moistened with
trichloroethane or isopropyl alcohol. Do not touch lamps directly with fingers.
5.2 Preventing Parts From Sticking
Before installation or after cleaning, spray or wipe platens with a light coat of release agent,
such as Miller-Stephenson MS-122* or Axel Mold-Wiz**. Coat only the side of the platen
that comes into contact with the part being terminated. Install the platens and run the Waffle
Iron through one operating cycle before making any terminations.
WARNING
When using release agent in pressurized containers, read and
observe all manufacturer’s precautions, warnings, and
instructions.
5.3 Upper Heat-Sink Hinge Adjustment
If the upper heat-sink hinge loosens up, so that the heat sink falls when released, tighten the
two hinge screws with a 9/64 inch hex key. The adjust-ment is correct when the upper heat
sink stays in place if released in any position, but moves without excessive resistance. Do not
lubricate hinges.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 15 of 16
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5.4 Troubleshooting
Troubleshooting Guide
Trouble Possible Cause Corrective Action
Tool will not Tool not plugged in Plug tool in
heat; all lights
remain off
Power (ON-OFF) switch Turn on power (ON-OFF)
not turned on switch
Circuit breaker tripped Turn on power (ON-OFF)
switch; if breaker trips
again, contact Raychem
field service.
Controller fault Contact Raychem field
service.
Flashing green Upper heat sink not Close and latch upper
READY/ERROR closed and latched heat sink.
light (Operator
error)
Previous termination Remove previous termination
not removed from (open upper heat
Waffle Iron II sink to cancel error)
Upper heat sink Close heat sink and press
opened during START button
heating cycle
Defective interlock Contact Raychem field
switch for upper service
heat sink.
Controller fault Contact Raychem field
service
Flashing red Hardware failure Contact Raychem field
FAULT light* service
*If the red FAULT light flashes, a wired-in internal fuse must be replaced and the failure must be
corrected. Contact Raychem field service to arrange for repairs.

Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 16 of 16
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5.5 Replacement Parts List
DESCRIPTION PART NUMBER
Infrared lamp (top or bottom) 966723
Reflector (top or bottom) 977842
Latch stud (for heat sink) 966243
Latch receptacle (for heat sink or 966722
cable clamp)
Cable clamp latch 966741
Cable clamp pads 966239
Fuse (fault) 3/8 amp,
Littlefuse