TE Connectivity 2161651 Series Customer'S Manual Download Page 1

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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

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

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

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

SYSTEM III TERMINAL SERVO FEEDER OPERATION AND CALIBRATION ............... 34

4.1.

Feeder Operation ...................................................................................................... 34

4.2.

Feeder Calibration ..................................................................................................... 35

TERMINATION QUALITY .................................................................................................. 37

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

RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION .................... 41

REVISION SUMMARY ....................................................................................................... 41

Smart Applicator Machine Integration Kits 2161651-[ ]

With Precision Controller Integration Kits 2161650-[ ]

and Direct Integration Kits 2161655-[ ]

STR

TIONS

Downloaded From

Oneyac.com

Summary of Contents for 2161651 Series

Page 1: ... 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 O...

Page 2: ...se 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 adjustmen...

Page 3: ...r 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 c...

Page 4: ...makers 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...

Page 5: ...roughly 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 operato...

Page 6: ...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 Downloaded From Oneyac com ...

Page 7: ...ine 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 ...

Page 8: ...gure 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 Dow...

Page 9: ...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 Ac...

Page 10: ...stallation 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 d...

Page 11: ...he following IP address h Add the IP address and Subnet mask as shown in Figure 12 i When complete click OK and then close all the dialog windows Figure 12 For Windows 7 operating system software a Install the USB to the Ethernet converter included with smart applicator machine integration kit 2161651 1 After the software installs the drivers proceed with the next step b Click the Start button and...

Page 12: ... a Click License on the right hand side See Figure 13 b Click Add and enter the license key See Figure 13 Figure 13 4 Configure the settings for the station to enable the smart applicator functions NOTE When configuring a station to have an applicator direct connection make sure to select the appropriate USB device ID using the Config button NOTE If using the precision controller make sure to enab...

Page 13: ...ire converter in the connection box If there is no USB device ID when the Config button is pressed then it may be necessary to insert the USB to one wire converter first This may require the software driver to be installed according to step 1 of Paragraph 2 4 Integration of Hardware and Software 8 Click OK to save the settings 9 Repeat steps 4 5 6 and 7 for each terminator that will have a smart a...

Page 14: ...the machine will always check for the applicator crimp height and cross section for the installed smart applicator on the terminator and display a warning When the smart applicator setting is turned on the machine will always check for a smart applicator during the verification process prior to entering production During the verification process the data programmed in the machine is compared to th...

Page 15: ...s editor to allow production without a smart applicator attached 3 Check that the smart applicator setting for the terminator is configured correctly for the precision controller connection or an applicator direct connection Register Failed The precision controller and the machine failed to initialize the communication 1 Check that the air feed signal from the terminator to the precision controlle...

Page 16: ...ically b Continue to press the Add button until all of the cross section and crimp heights are added NOTE If the terminal name and crimp height are not set up in the terminal before the Verify and Learn button is pressed a screen will appear to allow the operator to map the terminal to a terminal in the applicator or to select the proper crimp height from the data in the smart applicator See Figur...

Page 17: ...controller as follows a Power up the precision controller b Click the right arrow until the Precision Controller icon is highlighted c Click the arrow to enter the IO Interface Page See Figure 22 d Click the right arrow to the Settings Page See Figure 22 Figure 22 If the Ethernet settings has an IP address the Ethernet connection is turned on as shown in Figure 23 If there is only one precision co...

Page 18: ...f 169 254 1 2 To change the IP address click the Up button until the last digit of the IP address is highlighted Click the Check button to enable the setting of the last digit of the IP address See Figure 24 Use the up down arrows to set the last digit to the desired number Refer to Figure 24 Then click the Check button again to accept the new IP address The IP address can be set from 1 to 9 NOTE ...

Page 19: ... See Figure 26 Figure 26 4 To view all the data in the smart applicator click the Info button Refer to Figure 27 This screen shows all the data from the smart applicator 5 To set the terminator counters click Maintenance When a smart applicator is attached to the terminator it is possible to go to the applicator Maintenance screen The smart applicator has 10 tool counters Each counter has a descri...

Page 20: ... changes See Figure 28 Figure 28 2 4 Integration of Hardware and Software 1 When the software is installed on Windows XP the USB Host for One Wire Network for using WinUSB files are copied to the hard drive When the USB to one wire adapter is plugged into the USB port of the computer the software driver will need to be installed To install the driver follow the USB One Wire Converter Software Driv...

Page 21: ...ntroller can be described as three functional sections See Figure 31 the top of the controller contains the controller screen below the screen are the controller screen navigation keys and below the controller screen navigation keys are the feeder control or operation keys Figure 31 Click Finish New Hardware Wizard Searching Power Indicator Controller Screen Controller Screen Navigation Keys Feede...

Page 22: ... entry fields Also use these keys to navigate inside pop up selection boxes and spin boxes such as Terminal Selection and Trigger 1 Dwell See Figure 33 Use the Left and Right navigation keys to move through any subpages that are available for the currently displayed page NOTE It will first be necessary to navigate down to the subpage label using the Up and Down navigation keys and then switch to t...

Page 23: ...on holding this key will shorten the feed pitch Adjustments will be lost unless entered before using other Motion keys except the Reduce Feed Pitch Adjustment key Refer to Note 1 Reduce Feed Pitch Adjustment Key This indicator lights when the feed finger is retracted In this position the feed pitch may be adjusted See Note 1 Feed Full Cycle Key Pressing and holding this key will run a complete ful...

Page 24: ...tom of the menu will appear to indicate this process has begun See Figure 36 Figure 36 5 When the feeder has completed its necessary movements the Apply and Abort pushbuttons will become visible Install the calibration gage and move the feeder by hand until it is in the gage position See Figure 37 NOTE Use the Up and Down navigation keys to toggle between the Apply and Abort 6 When the appropriate...

Page 25: ... box Then save a selection by pressing the Enter key or cancel and exit by pressing the Cancel key Figure 38 3 Use the Down navigation key to move to Trigger1 Dwell See Figure 39 To change the value of the Trigger1 Dwell field a Click the Enter key to enter the field b Small Up and Down arrow keys will appear inside the field box for Trigger1 Dwell See Figure 39 Use the arrow keys to increase or d...

Page 26: ...p or down actuates the air feed when the terminator is going up or down For the precision controller either setting is suitable Start of air feed from bottom dead center range is 0 0 to 40 mm For the precision controller use a setting of 0 mm Actuation time range is 100 to 1000 ms For the precision controller use a setting of 220 ms The settings for the Komax leadmaker integration should be set to...

Page 27: ...inal box See Figure 42 NOTE Any feeder positional changes saved will be associated with the displayed terminal 6 After any terminal changes have been made the feeder should be homed To home the feeder press and hold the Extend Feed Finger key The home position is the extend position that places the terminal over the applicator anvil for the next terminator cycle NOTE When using the machine integra...

Page 28: ...ng the initial setting that is recommended See Figure 43 The Up and Down arrow keys can be used to scroll through the data NOTE The Wire Chart screen is a view only screen Information will not be reset or saved 2 Press the Enter key When the Wire Chart pushbutton is activated a screen similar to the screen shown in Figure 43 will appear Figure 43 Run Page Terminal Data 1 Use the Up and Down naviga...

Page 29: ...he crimp tooling this value is initially calculated but is easily changed and automatically saved when you adjust the feed extend position Feed Retract Position the feed retract position is the product feed pitch of the terminals this value is initially calculated but is easily changed and automatically saved when you adjust the feed retract position Feed Rate manufacturer s set speed or motion pr...

Page 30: ...cator that is connected Maintenance information for the individual tooling parts is available by using the Tooling button shown in Figure 47 which displays the Tooling screen shown in Figure 47 This screen contains information on individual pieces of tooling Figure 47 Data descriptions are as follows Tool manufacturer s description of the tool Part Number manufacturer s part number of the tool Cou...

Page 31: ...libration page is shown in Figure 48 Refer to Paragraph 3 2 Feeder Calibration for description Maintenance Page This page displays the maintenance information including the cycle count and feeder ID unique identifier of the feeder See Figure 48 The maintenance page also has a grayed out Maintenance Completed pushbutton that will become active when feeder maintenance is required A pop up message wi...

Page 32: ...re 49 Figure 49 Settings Page On this page the language can be changed by moving to the Language Edit field using the Up and Down arrow keys and then pressing the Enter key A pop up selection box will appear the user can scroll to the appropriate language and press the Enter key to select it Ethernet settings are used for TE internal use and typically should be left alone See Figure 50 LCD calibra...

Page 33: ...label and then to the Test pushbutton The Enter key must be pressed to enter the test It will become quite obvious if any of these keys do not work After the user enters the keyboard test the screen shown in Figure 51 will be displayed The user can test each key by pressing it Press the Enter key last Pressing Enter exits the keyboard test As each key is pressed its image is displayed on the scree...

Page 34: ... the data can be displayed though the software in the system III precision controller Figure 54 shows the side feed finger assembly and the end feed finger assembly The side feed finger features a replaceable tip that can be flipped over to provide an additional feed tip Note the orientation of the quick release pin shown in Figure 54 Figure 54 2 Flip the side feed finger into the up position A sp...

Page 35: ...eed In Extended Position indicator shown in Figure 34 lights before a crimp cycle is triggered 4 2 Feeder Calibration 1 Disconnect the feeder from the applicator and remove the feed finger DANGER To prevent personal injury keep fingers clear of the feed finger The next step will cause motion 2 Select Calibrate from the Feeder Page screen When prompted install the feeder calibration gage See Figure...

Page 36: ...rough the gage block and feed arm If the quick release pin does not pass completely through the feed arm loosen feed arm screws as shown in Figure 59 and move the feed arm Figure 59 6 Re tighten all the loose hardware 7 Select the Apply button in the Feeder Page screen 8 Remove the calibration assembly Feeder Calibration Gage Gage Block Position Feed Arm Does Not Enter Gage Block Four Latch Plate ...

Page 37: ...mproper adjustments rather than machine malfunctions These problems will generally manifest themselves as one of the poor quality terminations shown in Figure 60 Figure 60 Cont d Terminations Unacceptable with Causes Result of Poorly Adjusted Applicator Terminated Correctly Side Feed Terminals Downloaded From Oneyac com ...

Page 38: ...409 32023 Rev B 38 of 41 Figure 60 Cont d Terminations Unacceptable with Causes Result of Poorly Adjusted Applicator Terminated Correctly End Feed Terminals Downloaded From Oneyac com ...

Page 39: ...way Between Insulation Barrel Crimp and Wire Barrel Crimp Insulation Does Not Protrude No Brush Wire Protrusion Adjustment Incorrect Adjust Wire Protrusion Insulation Does Not Protrude Sideways Kink in Wire ST Position Relative to Wire Transfer Adjustment is Incorrect Insulation Does Not Protrude Little or No Brush Tonk Adjustment is Incorrect Up and Down Kink in Wire Downloaded From Oneyac com ...

Page 40: ...r and pivot hole Refer to Figure 61 Figure 61 7 Re install the guards and calibrate feeder DANGER To avoid personal injury the feeder should not be operated without guards in place The feeder guard is an integral structural element required for proper function of feeder Ten Million Cycles of Feeder Operation Every ten million cycles of feeder operation perform the following recommended preventive ...

Page 41: ... III precision controller in addition to powering down the bench top terminator or leadmaker prior to clearing a jam Otherwise injury is possible 2 Clear the jam refer to the respective machine customer manual 3 Turn the system III precision controller back on 4 Position the terminal over the anvil 5 Resume production 6 4 Precision Controller Maintenance There are no serviceable components in the ...

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