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molex 62300-6100, Instruction Manual

The Molex 62300-6100 instruction manual is a comprehensive guide to ensure hassle-free setup and operation of this remarkable product. It contains detailed step-by-step instructions, diagrams, and important safety information. Download this manual for free at our website and unlock the full potential of your Molex 62300-6100.

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RAST 5.0 Semi-Automatic Terminator Machine 

Doc: No: ATS-623006100 

Release Date: 04-28-09 

UNCONTROLLED COPY

 

Page 1 of 65 

Revision: A 

Revision Date: 04-28-09 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

RAST 5.0 SEMI-AUTOMATIC TERMINATOR MACHINE 

For Appli-Mate

™

 Connectors (12 and 16 AMP) 

Order No. 62300-6100 

Instruction Manual 

 
 
 
 
 
 

 

Description 

 

Operation 

 

Maintenance 

Summary of Contents for 62300-6100

Page 1: ...S 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 1 of 65 Revision A Revision Date 04 28 09 RAST 5 0 SEMI AUTOMATIC TERMINATOR MACHINE For Appli Mate Connectors 12 and 16 AMP Order No 62300 6100 Instruction Manual Description Operation Maintenance ...

Page 2: ...F 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 ...

Page 3: ...ROLLED COPY Page 3 of 65 Revision A Revision Date 04 28 09 Table of Contents 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 ...

Page 4: ...o ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 4 of 65 Revision A Revision Date 04 28 09 Section 1 General Description 1 1 Description 1 2 Technical Specifications 1 3 Applicable Products and Wires 1 4 Delivery Check 1 5 Cє Certificate ...

Page 5: ...8AWG 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 Compliance Complies with the general health and safety requirements in accordance with Counci...

Page 6: ... Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 6 of 65 Revision A Revision Date 04 28 09 Section 2 Start Up Shut Down Procedures 2 1 General Operation 2 2 Machine Operation and Process Flow 2 3 Operator Set Up And Functions ...

Page 7: ...set 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 An Emergency Stop Or Guard Interrupt 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 sen...

Page 8: ...and Process Flow 2 2 1 Connector Infeed 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 sid...

Page 9: ...tor 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 Knur...

Page 10: ...onnector 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 Tooling 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 Thi...

Page 11: ...e 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 Termination Station 1 The connector is automatically terminated after all the wires have been inserted correctly 2 The termination t...

Page 12: ...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 Supp...

Page 13: ...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 h...

Page 14: ...ppear 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 Machine Er...

Page 15: ...achine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 15 of 65 Revision A Revision Date 04 28 09 Section 3 Message Fault Display and Maintenance 3 1 Fault Displays 3 2 Maintenance 3 3 Perishable Tooling 3 4 Spare Parts ...

Page 16: ...Indicators Name Indicator Description LED Green Solid Green Wire inserted Speaker Audible beep Wire inserted 3 2 Maintenance 3 2 1 Cleaning 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 fl...

Page 17: ...s damaged airlines and gauges Monthly Check General condition of all tooling 6 Months 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 ...

Page 18: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 18 of 65 Revision A Revision Date 04 28 09 Section 4 Touch Screens and Troubleshooting ...

Page 19: ...tton 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 Screen 4 Safety Guard Open Screen This screen is displayed when the safety guard is open Close the guard and press the blue reset button on the main panel Screen 5 Sensor must be Homed Screen This is...

Page 20: ...been made in the current batch Insert Wire into Position 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 Screen 8 Sensor is Homing Screen This screen ...

Page 21: ... the Housing Feed Gripper Cylinder fails to activate sensor B0 09 Check to see if the tooling jammed or if something is stopping the cylinder from completing its stroke Clear the fault and press CLEAR button Air may have to be removed from the machine to clear the fault either by pressing Emergency Stop opening the guard door or disconnecting the air supply If any of these are done their respectiv...

Page 22: ...g the cylinder from completing its stroke Clear the fault and press CLEAR button Air may have to be removed from the machine to clear the fault either by pressing Emergency Stop opening the guard door or disconnecting the air supply If any of these are done their respective faults Emergency Stop Safety Guard Open or Air Pressure Low will take precedence on the display Screen 20 Mask Tooling not Do...

Page 23: ...alve is turned on 4 Air Pressure is set to 6 0 bar 85 psi 5 Air Safety valve is on 6 Air Leaks Screen 30 Manual Screen 1 This screen is displayed when Manual has been selected from the Ready to Run Screen or PREV has been selected from the Manual 2 Screen Hsg Stick Feed Button This button allows manual operation of the Housing Stick Feed Cylinder Pressing the button once will allow the cylinder to...

Page 24: ...s the screen to Manual Screen 1 SET UP Selects Set Up mode and changes the screen to the Set Up 1 Screen 40 MAIN Select Automatic mode and changes the screen to Ready to Run Screen 2 CLEAR Clears any faults Screen 40 Set Up 1 Screen This screen is displayed when the SET UP button is pressed on the Manual Screens or PREV has been selected from the Set Up 2 Screen CIRCUIT SIZE This displays the curr...

Page 25: ... Changes the screen to Set Up Screen 1 Screen 40 NEXT Changes the screen to Set Up Screen 4 Screen 43 MAIN Changes the screen to Ready to Run Screen Screen 2 Screen 43 Set Up Screen 4 This screen is displayed when NEXT has been selected from the Set Up 3 Screen SELECT LANGUAGE This allows language selection for the screen display When the screens are displayed in English pressing TURKISH will auto...

Page 26: ...ne Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 26 of 65 Revision A Revision Date 04 28 09 Section 5 Assembly Drawings Electrical and Pneumatic Diagrams 5 1 Assembly Drawings 5 2 Electrical Drawings 5 3 Pneumatic Drawings ...

Page 27: ...00 6105 Cut and Termination Slide Assembly 1 7 62300 6106 In Feed Gripper Assembly 1 8 62300 6107 Laser Sensor Assembly 1 9 62300 6214 Out Feed Pawl Assembly 1 10 62300 6108 Mask Tooling Assembly 1 11 62300 6216 IOP Box Assembly 1 12 62300 6217 Guard 1 13 62300 6218 Polycarb Guard 1 14 62300 6219 Guard 1 15 62300 6220 Guard 1 16 62300 6221 Cabinet Skirt 1 17 62300 6222 Stainless Guard 1 18 62300 6...

Page 28: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 28 of 65 Revision A Revision Date 04 28 09 3 7 6 22 23 1 2 16 10 5 8 9 11 19 20 Main Assembly ...

Page 29: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 29 of 65 Revision A Revision Date 04 28 09 4 14 15 13 24 21 17 11 9 7 12 18 Main Assembly ...

Page 30: ...m Order No Description Qty 1 62300 6114 Termination Track 1 2 62300 6115 Comb Tooling 1 3 62300 6116 Entry Cover 1 4 62300 6117 Exit Cover 1 5 62300 6118 Wire Support Plate 1 6 62300 6119 Termination Track Brake 1 7 62300 6052 Left Push Finger 1 8 62300 6053 Right Push Finger 1 9 N A C Spring Entex 3302 1 10 N A C Spring Entex 3166 2 11 N A Dowel Pin 4 0 Diameter g6 by 25mm 2 12 REF Customer Produ...

Page 31: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 31 of 65 Revision A Revision Date 04 28 09 Termination Track Assembly ...

Page 32: ...pright 1 8 62300 6250 Top Plate 1 9 62300 6251 Gusset 2 10 62300 6252 Termination Adjust Plate 1 11 62300 6253 Top Front Plate 1 12 62300 6254 Front Cover 1 13 62300 6255 Guide Plate 1 14 62300 6256 Infeed Table Mtg Plate 2 15 62300 6257 Cylinder Mtg Plate 1 16 62300 6258 Cut Loose St Support Plate 1 17 62300 6259 Termination Slide Mtg Plate 1 18 62300 6260 Rear Hinged Cover 1 19 N A Transfer Cyli...

Page 33: ...omatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 33 of 65 Revision A Revision Date 04 28 09 18 16 4 23 17 5 25 1 12 7 20 10 2 14 21 6 6 15 19 22 24 3 8 4 13 11 9 Frame Assembly ...

Page 34: ...00 6262 Cylinder Pivot Block 1 3 62300 6263 Fixed Pivot Block 2 4 62300 6264 Fixed Link Arm 1 5 62300 6265 Moving Link Arm 1 6 62300 6266 Toggle Joint 1 7 62300 6267 End Plate 1 8 62300 6268 Toggle Joint Pivot Pin 1 9 62300 6269 Brass Washer 1 12 N A Flange Bushing Oilite AMF1521 25 2 13 N A Straight Bushing Oilite AMC1215 16 2 14 N A Compact Cylinder Festo ADN 80 40 A P A 1 15 N A Swivel Flange F...

Page 35: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 35 of 65 Revision A Revision Date 04 28 09 Toggle Joint Assembly ...

Page 36: ...nt Plate 1 3 62300 6272 Adjustable Side Guide 1 4 62300 6273 Fixed Side Guide 1 5 62300 6274 Push Bar Mtg Block 1 6 62300 6275 Tie Rod Connect Block 1 7 62300 6276 Push Bar 1 8 62300 6120 Push Bar Support 1 9 62300 6282 Push Bar End Stop 1 10 62300 6284 Rail Support Block 2 11 62300 6121 In Feed Table Rast 5 16AMP 1 12 62300 6122 Cut Station Rast 5 16AMP 1 13 N A Knob Ganter Griff GN 6335 4 TE 32 ...

Page 37: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 37 of 65 Revision A Revision Date 04 28 09 In Feed Table Assembly ...

Page 38: ...mination Slide Assembly 62300 6105 Item Order No Description Qty 1 62300 6101 Housing Cut Blade 1 2 62300 6102 Termination Tool 1 3 62300 6285 Cut and Termination Tooling Plate 1 4 62300 6286 Toggle To Slide Linkage 1 5 62300 6287 Toggle Joint Pin 1 6 62300 6288 Cut and Termination Tooling Key 1 7 62300 6289 Brass Washer 2 8 N A Rail and Carriage THK SRS15WMUU 190L 1 9 N A Bush Oilite AMC1620 12 2...

Page 39: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 39 of 65 Revision A Revision Date 04 28 09 Cut and Termination Assembly ...

Page 40: ...tem Order No Description Qty 1 62300 6291 In Feed Cylinder Mtg Plate 1 2 623006129 Fixed Clamp Plate 1 3 62300 6293 Adjustable Clamp Plate 1 4 62300 6294 Clamp Cylinder Plate 1 5 623006130 In Feed Moving Clamp 1 6 623006131 Cylinder Spacer Block 1 7 623006132 Cylinder Spacer Block 1 8 N A Thumbscrew Ganter Griff DIN 653 M6 16 1 9 N A Cylinder Festo DFM 16 20 P A GF 1 10 N A Compact Cylinder Festo ...

Page 41: ... 6107 Item Order No Description Qty 1 62300 6298 Mounting Feet 2 2 62300 6134 Slide Mtg Plate 1 3 62300 6298 Sensor Mtg Block 1 4 N A Location Pins Festo 150928 ZBS 5 2 5 N A Displacement Sensor Omron ZX LD40 1 6 N A Festo Linear Slide and Stepper Motor Items7 thru 10 REF 7 N A Festo KSE 15 22 D04 D05 1 8 N A Festo MTR ST 42 48S AA 1 9 N A Festo MTR FL30 ST42 FLANGE 1 10 N A Festo DGE 12 100 ZR LV...

Page 42: ...02 Out Feed Pawl Mtg Plate 1 2 62300 6403 Out Feed Pawl Body 1 3 62300 6404 Out Feed Pawl Body 1 4 62300 6405 Out Feed Pawl Adjust Block 1 5 62300 6406 Pawl Pivot Pin 1 6 N A Rail and Carriage THK RSH15ZMUU 190L 1 8 N A Floating Joint Festo 2061 FK M6 0 0 2 9 N A Tension Spring Entex 521 TENSION 1 10 N A Spring Post Misumi BSPL4 25 1 11 N A Nut Misumi ANN 4 1 12 N A Hard Stop Misumi ANB 4 20 1 13 ...

Page 43: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 43 of 65 Revision A Revision Date 04 28 09 Out Feed Pawl Assembly ...

Page 44: ...Description Qty 1 62300 6123 Main Slide Plate 1 2 62300 6124 Cylinder Clevis Block 1 3 623006415 Floating Joint 1 4 62300 6416 Gripper Pivot Pin 1 5 62300 6125 Cable Mask Tooling 1 6 62300 6126 Spring Retaining Block 1 7 62300 6127 Comb Tooling Trigger Pin 2 8 623006128 Mask Tooling Grip Insert 12 9 N A Rail and Carriage THK SRS 9WM 1 10 N A Cylinder Festo DMM 20 20 P A 1 11 N A Compression Spring...

Page 45: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 45 of 65 Revision A Revision Date 04 28 09 B 1 50 1 Wire Mask Tooling ...

Page 46: ...No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 46 of 65 Revision A Revision Date 04 28 09 2 1 OMRON HMI SCREEN IOP Box Assembly IOP Box Assembly 62300 6216 Item Order No Description Qty 1 623006417 IOP Box 1 2 623006418 Lexan Label 1 ...

Page 47: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 47 of 65 Revision A Revision Date 04 28 09 5 2 Electrical Parts List ...

Page 48: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 48 of 65 Revision A Revision Date 04 28 09 ...

Page 49: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 49 of 65 Revision A Revision Date 04 28 09 ...

Page 50: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 50 of 65 Revision A Revision Date 04 28 09 5 2 Electrical Drawings ...

Page 51: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 51 of 65 Revision A Revision Date 04 28 09 ...

Page 52: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 52 of 65 Revision A Revision Date 04 28 09 ...

Page 53: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 53 of 65 Revision A Revision Date 04 28 09 ...

Page 54: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 54 of 65 Revision A Revision Date 04 28 09 ...

Page 55: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 55 of 65 Revision A Revision Date 04 28 09 ...

Page 56: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 56 of 65 Revision A Revision Date 04 28 09 ...

Page 57: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 57 of 65 Revision A Revision Date 04 28 09 ...

Page 58: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 58 of 65 Revision A Revision Date 04 28 09 ...

Page 59: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 59 of 65 Revision A Revision Date 04 28 09 ...

Page 60: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 60 of 65 Revision A Revision Date 04 28 09 ...

Page 61: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 61 of 65 Revision A Revision Date 04 28 09 ...

Page 62: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 62 of 65 Revision A Revision Date 04 28 09 Control Box Assembly ...

Page 63: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 63 of 65 Revision A Revision Date 04 28 09 5 3 Pneumatic Diagrams ...

Page 64: ...RAST 5 0 Semi Automatic Terminator Machine Doc No ATS 623006100 Release Date 04 28 09 UNCONTROLLED COPY Page 64 of 65 Revision A Revision Date 04 28 09 ...

Page 65: ...79 0002 91779 0003 91779 0004 91779 0005 91779 0006 917790007 91779 0008 91779 0009 91779 0010 91779 0019 2 91779 9001 91779 9002 91779 9003 91779 9004 91779 0101 91779 0102 91779 0103 91779 0104 91779 0105 91779 0106 91779 0107 91779 0108 91779 0109 91779 0110 91779 0111 91779 0112 91779 0113 91779 0114 91779 0115 91779 0116 91779 9101 91779 9102 917799 103 91779 9104 91779 9105 3 91779 9106 9177...

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