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molex RAST 5.0 Instruction Manual

Semi-automatic terminator machine
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RAST 5.0 Semi-Automatic Terminator Machine
RAST 5.0 SEMI-AUTOMATIC TERMINATOR MACHINE
Description
Operation
Maintenance
Doc: No: ATS-623006100
Revision: A
For Appli-Mate
™
Connectors (12 and 16 AMP)
Order No. 62300-6100
Instruction Manual
Release Date: 04-28-09
Revision Date: 04-28-09
UNCONTROLLED COPY
Page 1 of 65

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  • Page 1 RAST 5.0 Semi-Automatic Terminator Machine RAST 5.0 SEMI-AUTOMATIC TERMINATOR MACHINE For Appli-Mate ™ Connectors (12 and 16 AMP) Order No. 62300-6100 Instruction Manual Description Operation Maintenance UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 1 of 65 Revision: A...
  • Page 2 RAST 5.0 Semi-Automatic Terminator Machine WARNING NEVER USE THIS FIXTURE WITHOUT THE GUARDING OR OTHER SAFETY DEVICES IN PLACE, GUARD DOORS CLOSED AND GUARD OVERRIDE SWITCHED “OFF”. FIXTURE GUARDING IS DESIGNED TO PREVENT HANDS FROM REMAINING IN THE DANGER AREAS OF THE FIXTURE.
  • Page 3 RAST 5.0 Semi-Automatic Terminator Machine Table of Contents SECTION General Description Start Up / Shut Down Procedures Message Fault Display and Maintenance Touch Screens and Troubleshooting Assembly Drawings, Electrical and Pneumatic Diagrams Connector Series Chart UNCONTROLLED COPY Doc: No: ATS-623006100...
  • Page 4 RAST 5.0 Semi-Automatic Terminator Machine 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 UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 4 of 65 Revision: A Revision Date: 04-28-09...
  • Page 5 The 62300-6100 APPLI-MATE™ (RAST 5.0) container and determine that the following items Semi-Automatic Terminator Machine, is designed are included in the package. to terminate the APPLI-MATE™ (RAST 5.0) female connector series (90835, 91779, and Order No. 92000) onto discrete wire (1.0-1.5 mm...
  • Page 6 RAST 5.0 Semi-Automatic Terminator Machine Section 2 Start-Up / Shut Down Procedures 2.1. General Operation Machine Operation and Process Flow Operator Set Up And Functions UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 6 of 65 Revision: A Revision Date: 04-28-09...

  • Page 7: General Operation

    RAST 5.0 Semi-Automatic Terminator Machine General Operation 2.1.1 Preliminary 1. Connect air supply to fixture. Use 6mm nylon air hose in the quick-fitting. 2. Turn on mains power Isolator. 3. Release Emergency-stop push buttons if necessary. 2.1.2 System Start-Up (When above conditions are met) 1.
  • Page 8 RAST 5.0 Semi-Automatic Terminator Machine Semi-Automatic Terminator Machine Operation 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.
  • Page 9 RAST 5.0 Semi-Automatic Terminator Machine Clamping Cylinder Knurled Screw to tighten/release the adjustable gripper jaw Rail Clamp Screw 2.2.2 Connector Separate (Cut Loose) 1. In the automatic mode the connectors are transferred to the cut station by the connector feed.
  • Page 10 RAST 5.0 Semi-Automatic Terminator Machine 2.2.3 Connector Transfer 1. After a row of connectors has been separated they are transferred to the termination position. 2. After a connector has been inserted with wires and has been terminated the finished assembly is transferred out of the terminating station while the newly separated connector enters.
  • Page 11 RAST 5.0 Semi-Automatic Terminator Machine 2.2.5 Wire Sensor 1. A laser sensor detects that the wires are inserted to the proper depth in the connector. 2. According to the connector circuit size and corresponding program selected by the operator (See section 2.3.4) the machine detects when the correct amount of wires have been inserted successfully.
  • Page 12 RAST 5.0 Semi-Automatic Terminator Machine Operator Set-Up and Functions Note: A wire must be inserted for functions 2.3.1 Machine Run “STOP” or “REDO” to be available on the touch screen. To Power Up 1. Turn on main disconnect switch on electrical For detailed explanations of touch screens see cabinet door.
  • Page 13 RAST 5.0 Semi-Automatic Terminator Machine must be able to slide easily. Retighten the clamp 4. The mask tooling has spring loaded inserts screws. which will keep the wires held in position until 3. Loosen the knurled screw at the clamping the connector has been terminated.
  • Page 14 RAST 5.0 Semi-Automatic Terminator Machine Wire. Ensure that unused circuit positions 2.3.6 Program Selection (Circuit Size) have N. f. From Select Wire Positions. Press “Main” to 1. When circuit size (or number of wires loaded) return to Ready to Run.
  • Page 15 RAST 5.0 Semi-Automatic Terminator Machine Section 3 Message Fault Display and Maintenance Fault Displays Maintenance Perishable Tooling Spare Parts UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 15 of 65 Revision: A Revision Date: 04-28-09...

  • Page 16: Fault Displays

    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 flying out at the operator 3.2.2 Lubrication...

  • Page 17: 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 of the perishable tool kits in stock at all times. This will reduce the amount of production down time.
  • Page 18 RAST 5.0 Semi-Automatic Terminator Machine Section 4 Touch Screens and Troubleshooting UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 18 of 65 Revision: A Revision Date: 04-28-09...

  • Page 19: Touch Screens

    RAST 5.0 Semi-Automatic Terminator Machine Touch Screens Screen 1 Screen 4 Start Up Screen Safety Guard Open Screen This screen appears after the machine has been powered up. This screen is displayed when the safety guard is It is only an information screen.
  • Page 20 RAST 5.0 Semi-Automatic Terminator Machine Parts Made:Displays how many parts have been This screen is displayed after the Home Sensor made in the current batch. Button has been pressed on Screen 5. When the Insert Wire into Position: Displays the position sensor reaches the home position the Ready to Run where the current wire is to be inserted.
  • Page 21 RAST 5.0 Semi-Automatic Terminator Machine the cylinder from completing its stroke. Clear the Air may have to be removed from the machine to fault and press CLEAR button. clear the fault either by pressing Emergency Stop, opening the guard door or disconnecting the air Air may have to be removed from the machine to supply.
  • Page 22 RAST 5.0 Semi-Automatic Terminator Machine Air may have to be removed from the machine to opening the guard door or disconnecting the air clear the fault either by pressing Emergency Stop, supply. If any of these are done their respective opening the guard door or disconnecting the air faults (“Emergency Stop”, “Safety Guard Open”, or...
  • Page 23 RAST 5.0 Semi-Automatic Terminator Machine faults (“Emergency Stop”, “Safety Guard Open”, or Screen 30 “Air Pressure Low”) will take precedence on the Manual Screen #1 display. This screen is displayed when Manual has been Screen 22 selected from the Ready to Run Screen or PREV Termination Tooling not Down Fault Screen has been selected from the Manual #2 Screen.
  • Page 24 RAST 5.0 Semi-Automatic Terminator Machine CIRCUIT SIZE: This displays the current circuit size This screen is displayed when the NEXT button is of the connectors being processed. pressed on Manual Screen #1. Hsg Feed Button:This button allows manual ENTER CIRCUIT SIZE: This button allows the operation of the Housing Feed Cylinder.
  • Page 25 RAST 5.0 Semi-Automatic Terminator Machine SELECT WIRE POSITIONS: This allows selection Screen 43 of wires that are to be loaded in the connector. Set Up Screen #4 Pressing the number of the wire position will either select or deselect the presence of a wire in that position.
  • Page 26 RAST 5.0 Semi-Automatic Terminator Machine Section 5 Assembly Drawings, Electrical and Pneumatic Diagrams Assembly Drawings Electrical Drawings Pneumatic Drawings UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 26 of 65 Revision: A Revision Date: 04-28-09...

  • Page 27: Main Assembly

    RAST 5.0 Semi-Automatic Terminator Machine 5.1 Main Assembly Main Assembly 62300-6100 Item Order No. Description Qty. 62300-6206 Table Top 62300-6103 Termination Track Assembly 62300-6208 Frame Assembly 62300-6209 Toggle Joint Assembly 62300-6104 In-Feed Table Assembly 62300-6105 Cut and Termination Slide Assembly...
  • Page 28 RAST 5.0 Semi-Automatic Terminator Machine Main Assembly 19 20 UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 28 of 65 Revision: A Revision Date: 04-28-09...
  • Page 29 RAST 5.0 Semi-Automatic Terminator Machine Main Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 29 of 65 Revision: A Revision Date: 04-28-09...
  • Page 30 Left Push Finger 62300-6053 Right Push Finger C-Spring Entex #3302 C-Spring Entex #3166 Dowel Pin 4.0 Diameter g6 by 25mm Customer Product- Rast 5.0 16 AMP UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 30 of 65 Revision: A...
  • Page 31 RAST 5.0 Semi-Automatic Terminator Machine Termination Track Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 31 of 65 Revision: A Revision Date: 04-28-09...
  • Page 32 RAST 5.0 Semi-Automatic Terminator Machine Frame Assembly Frame Assembly 62300-6208 Item Order No. Description 62300-6243 Left Frame Upright 62300-6244 Right Frame Upright 62300-6245 Front Cover Plate 62300-6246 Right Track Upright 62300-6247 Left Track Upright 62300-6248 THK Slide Bkt. 62300-6249 Back Frame Upright...
  • Page 33 RAST 5.0 Semi-Automatic Terminator Machine Frame Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 33 of 65 Revision: A Revision Date: 04-28-09...
  • Page 34 RAST 5.0 Semi-Automatic Terminator Machine Toggle Joint Assembly Toggle Joint Assembly 62300-6209 Item Order No. Description Qty. 62300-6261 Fixed Pivot Pin 62300-6262 Cylinder Pivot Block 62300-6263 Fixed Pivot Block 62300-6264 Fixed Link Arm 62300-6265 Moving Link Arm 62300-6266 Toggle Joint...
  • Page 35 RAST 5.0 Semi-Automatic Terminator Machine Toggle Joint Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 35 of 65 Revision: A Revision Date: 04-28-09...
  • Page 36 RAST 5.0 Semi-Automatic Terminator Machine In-Feed Table Assembly In-Feed Table Assembly 62300-6104 Item Order No. Description Qty. 62300-6270 In-Feed Table 62300-6271 In-Feed Front Plate 62300-6272 Adjustable Side Guide 62300-6273 Fixed Side Guide 62300-6274 Push Bar Mtg. Block 62300-6275 Tie Rod Connect Block...
  • Page 37 RAST 5.0 Semi-Automatic Terminator Machine In-Feed Table Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 37 of 65 Revision: A Revision Date: 04-28-09...
  • Page 38 RAST 5.0 Semi-Automatic Terminator Machine Cut and Termination Slide Assembly Cut and Termination Slide Assembly 62300-6105 Item Order No. Description Qty. 62300-6101 Housing Cut Blade 62300-6102 Termination Tool 62300-6285 Cut and Termination Tooling Plate 62300-6286 Toggle To Slide Linkage 62300-6287...
  • Page 39 RAST 5.0 Semi-Automatic Terminator Machine Cut and Termination Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 39 of 65 Revision: A Revision Date: 04-28-09...
  • Page 40 RAST 5.0 Semi-Automatic Terminator Machine In-Feed Gripper Assembly In-Feed Gripper Assembly 62300-6106 Item Order No. Description Qty. 62300-6291 In-Feed Cylinder Mtg. Plate 623006129 Fixed Clamp Plate 62300-6293 Adjustable Clamp Plate 62300-6294 Clamp Cylinder Plate 623006130 In-Feed Moving Clamp 623006131 Cylinder Spacer Block...
  • Page 41 RAST 5.0 Semi-Automatic Terminator Machine Laser Sensor Assembly Laser Sensor Assembly 62300-6107 Item Order No. Description Qty. 62300-6298 Mounting Feet 62300-6134 Slide Mtg. Plate 62300-6298 Sensor Mtg. Block Location Pins- Festo -150928 ZBS-5 Displacement Sensor- Omron - ZX-LD40 Festo Linear Slide and Stepper Motor (Items7 thru 10) REF...
  • Page 42 RAST 5.0 Semi-Automatic Terminator Machine Out-Feed Pawl Assembly Out-Feed Pawl Assembly 62300-6214 Item Order No. Description Qty. 62300-6402 Out-Feed Pawl Mtg. Plate 62300-6403 Out-Feed Pawl Body 62300-6404 Out-Feed Pawl Body 62300-6405 Out-Feed Pawl Adjust Block 62300-6406 Pawl Pivot Pin Rail and Carriage- THK -RSH15ZMUU+190L Floating Joint- Festo -2061 FK-M6-(0;0)
  • Page 43 RAST 5.0 Semi-Automatic Terminator Machine Out-Feed Pawl Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 43 of 65 Revision: A Revision Date: 04-28-09...
  • Page 44 RAST 5.0 Semi-Automatic Terminator Machine Wire Mask Tooling Wire Mask Tooling 62300-6108 Item Order No. Description Qty. 62300-6123 Main Slide Plate 62300-6124 Cylinder Clevis Block 623006415 Floating Joint 62300-6416 Gripper Pivot Pin 62300-6125 Cable Mask Tooling 62300-6126 Spring Retaining Block...
  • Page 45 RAST 5.0 Semi-Automatic Terminator Machine Wire Mask Tooling B (1.50:1) UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 45 of 65 Revision: A Revision Date: 04-28-09...
  • Page 46 RAST 5.0 Semi-Automatic Terminator Machine IOP Box Assembly IOP Box Assembly 62300-6216 Item Order No. Description Qty. 623006417 IOP Box 623006418 Lexan Label OMRON HMI SCREEN UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 46 of 65 Revision: A...

  • Page 47: Electrical Parts List

    RAST 5.0 Semi-Automatic Terminator Machine Electrical Parts List UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 47 of 65 Revision: A Revision Date: 04-28-09...
  • Page 48 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 48 of 65 Revision: A Revision Date: 04-28-09...
  • Page 49 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 49 of 65 Revision: A Revision Date: 04-28-09...

  • Page 50: Electrical Drawings

    RAST 5.0 Semi-Automatic Terminator Machine Electrical Drawings UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 50 of 65 Revision: A Revision Date: 04-28-09...
  • Page 51 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 51 of 65 Revision: A Revision Date: 04-28-09...
  • Page 52 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 52 of 65 Revision: A Revision Date: 04-28-09...
  • Page 53 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 53 of 65 Revision: A Revision Date: 04-28-09...
  • Page 54 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 54 of 65 Revision: A Revision Date: 04-28-09...
  • Page 55 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 55 of 65 Revision: A Revision Date: 04-28-09...
  • Page 56 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 56 of 65 Revision: A Revision Date: 04-28-09...
  • Page 57 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 57 of 65 Revision: A Revision Date: 04-28-09...
  • Page 58 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 58 of 65 Revision: A Revision Date: 04-28-09...
  • Page 59 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 59 of 65 Revision: A Revision Date: 04-28-09...
  • Page 60 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 60 of 65 Revision: A Revision Date: 04-28-09...
  • Page 61 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 61 of 65 Revision: A Revision Date: 04-28-09...
  • Page 62 RAST 5.0 Semi-Automatic Terminator Machine Control Box Assembly UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 62 of 65 Revision: A Revision Date: 04-28-09...

  • Page 63: Pneumatic Diagrams

    RAST 5.0 Semi-Automatic Terminator Machine 5.3 Pneumatic Diagrams UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 63 of 65 Revision: A Revision Date: 04-28-09...
  • Page 64 RAST 5.0 Semi-Automatic Terminator Machine UNCONTROLLED COPY Doc: No: ATS-623006100 Release Date: 04-28-09 Page 64 of 65 Revision: A Revision Date: 04-28-09...
  • Page 65 RAST 5.0 Semi-Automatic Terminator Machine Section 6 Connector Series Chart Products: 5.00mm (.197") Pitch Appli-Mate™ RAST 5.0 IDT Connector Assemblies 2, 3 and 4 Circuits. Connector Circuit Size Connector Assembly Order No. Series No. 90835-0001 90835-0003 90835-0019 90835-0034 90835-0035 90835-0036 90835-0037...

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62300-6100

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