1. Manuals
  2. Brands
  3. TE Connectivity Manuals
  4. Crimp tool
  5. 2161651 Series
  6. Customer's manual

TE Connectivity 2161651 Series Customer's Manual

Smart applicator machine integration kits, with precision controller integration kits and direct integration kits
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
© 2015 TE Connectivity family of companies
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
Smart Applicator Machine Integration Kits 2161651-[ ]
With Precision Controller Integration Kits 2161650-[ ]
and Direct Integration Kits 2161655-[ ]
1. 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
2. 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
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
4.1. Feeder Operation ...................................................................................................... 34
4.2. Feeder Calibration ..................................................................................................... 35
5. TERMINATION QUALITY .................................................................................................. 37
6. 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
8. REVISION SUMMARY ....................................................................................................... 41
TOOLING ASSISTANCE CENTER 1-800-722-1111
Downloaded From
READ THIS FIRST! .............................................. 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Oneyac.com
Customer Manual
409-32023
Rev B
02 MAR 15
1 of 41

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2161651 Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TE Connectivity 2161651 Series

Summary of Contents for TE Connectivity 2161651 Series

  • Page 1: Table Of Contents

    For latest revision and Regional Customer Service, All Rights Reserved visit our website at www.te.com. *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. Downloaded From Oneyac.com...

  • Page 2: Safety Precautions

    409-32023 SAFETY PRECAUTIONS — AVOID INJURY Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application equipment must be operated in a dry, dust-free environment.

  • Page 3: Introduction

    409-32023 System III Precision Controller Installed on Komax Leadmaker with mci 722 Terminator Figure 1 1. INTRODUCTION This customer manual covers the system III smart applicator integration kits used with Komax leadmakers with mci 722 terminators only. See Figure 1. When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

  • Page 4: Smart Applicator Precision Controller Integration Kit

    409-32023 1.3. Smart Applicator Precision Controller Integration Kit The precision controller integration kit consists primarily of a precision controller, system III terminal servo feeder, and the hardware that attaches the controller and feeder to the appropriate Komax leadmaker. The system III terminal servo feed assembly can be used in conjunction with system III applicators and Ocean applicators to provide the means for feeding terminals into the applicator for crimping.

  • Page 5: Smart Applicator Direct Integration Kit

    409-32023 1.4. Smart Applicator Direct Integration Kit The direct integration kit consists of cabling, which connects the smart applicator to the Komax leadmaker. This kit is typically used when no servo feed applicators are used. This kit allows direct reading of data from mechanical-feed and/or pneumatic-feed applicators.
  • Page 6 409-32023 Side Cover (Ref) Figure 3 Ball Lock Pin Modified Side Cover Cable Cradle Adapter Plate System III Precision Controller Run Power Cable and Communications Cable Through Here Feeder Holder Note: Refer to Drawing 2161650 for additional photos. Figure 4 6 of 41 Rev B Downloaded From...
  • Page 7 409-32023 Power and Communication Cables Routed Along Back Side of Terminator Cable Run Into Machine Excess Cable in Wire Way Note: Cover Removed for Clarity Access Cover Removed Figure 5 c. Remove the access cover, and run the cable into the machine. See Figure 5. Run the power cable into the main electrical box.
  • Page 8 409-32023 Computer Communications Cable Connected to USB Port on Main Computer Ethernet Communications Cable 2 Kits Shown Installed Figure 7 4. Route the trigger cable into the back of the terminator, and connect the trigger cable to the air feed cable.
  • Page 9 409-32023 See schematic 2161898 for connection. Ensure that the black wire (-) goes to the (-) and the red wire (+) goes to the (01). Refer to Figure 9. Red Wire Black Wire Figure 9 Installation of Direct Integration Kit 1.

  • Page 10: Software Installation

    409-32023 USB Hub Back Right Side Adapter of Terminator Cable Probe Phone Cable 2 Kits Shown Installed Inline Coupler Figure 11 2.3. Software Installation 1. Verify that the TopWin software version on the machine is: 12.4 or newer for Komax leadmaker A355, A355S, A356 13.2 or newer for Komax leadmaker G263 13.3 or newer for Komax leadmaker A488S 14.1 or newer for Komax leadmaker A477, A488...
  • Page 11 409-32023 Set Up Ethernet Port for System 1. Verify that the software version is correct according to step 1 of Paragraph 2.3. 2. Configure the host machine IP address to 169.254.1.100. For Windows XP operating system software: a. Install the USB to the Ethernet converter included with smart applicator machine integration kit 2161651-1.
  • Page 12 409-32023 g. In the center of the dialog, locate and double click “Internet Protocol Version 4(TCP/IPv4)” to open the Properties dialog. h. In the center of the new dialog, click "Use the following IP address". i. Add the "IP address" and "Subnet mask" as shown in Figure 12. 3.
  • Page 13 409-32023 2. Under “Tools”, click “Option Editor” (it may take time for the “Option Editor” to appear). See Figure 15. Click Tools (for Option Editor) Click Each Terminator That Will Have Smart Applicator Wrench Icon Air Feed Option Checked Smart Applicator Option Checked Configuration Figure 15...
  • Page 14 409-32023 Figure 16 12. At this point, the machine will have the smart applicator features installed. To use the data contained in the smart applicator, it is necessary to configure the terminals to be run in production properly. In addition to the terminal name, or mapped terminal, the crimp height and cross section can be verified as well.
  • Page 15 409-32023 If both boxes are not checked, the machine will complete the verification process and enter production when there is no smart applicator connected, but an error/warning will be displayed (click the OK button to continue). For possible error messages and solutions, refer to Figure 18. SMART APPLICATOR ERROR MESSAGE DESCRIPTION POSSIBLE SOLUTION...
  • Page 16 409-32023 13. There are several ways to configure a terminal for production using the data in the smart applicator. — Create/copy a terminal with a name that is in the applicator. — Create/copy a terminal with a user given name, and map this terminal to a terminal in the applicator. 14.
  • Page 17 409-32023 NOTE For detailed instructions, refer to Paragraph 2.3, Software Installation. 2. Configure the IP address on the precision controller. Each precision controller will connect to the machine (TEServerApp application) with a specific and unique IP address. If there are more than one precision controller in the system, it will be necessary to configure the IP address of each unit.
  • Page 18 409-32023 e. When the precision controller is connected to a Komax leadmaker, the IP address will need to be set. Click down until “Automatic Address” is highlighted as shown in Figure 22. Then click the Check button. This will uncheck the box with the X. The screen will change to show an IP address of 169.254.1.1 as shown in Figure 22.
  • Page 19 409-32023 2. In the Terminal Editor screen, there is a list of terminals programmed in the TopWin software. To see the list, click “Smart Applicator”. See Figure 26. 3. The pop-up screen shows the list of terminals and mapped terminals that are in the smart applicator. The smart applicator system will run only with the terminals listed here.

  • Page 20: Integration Of Hardware And Software

    409-32023 6. To change the values of a counter, click the tool listed in the Maintenance screen. — When the target count is set to a value, the counter is active. If the target is set to “0,” then the counter is not active.

  • Page 21: System Iii Precision Controller Operation

    409-32023 4. The New Hardware wizard will search and install the driver. See Figure 30. Then click “Finish”. See Figure 30. New Hardware Wizard Searching Click “Finish” Figure 30 At this point, the “USB Host for One-Wire Network” is installed. 3.

  • Page 22: Controller Screen, Navigation, And Operation

    409-32023 3.1. Controller Screen, Navigation, and Operation Controller Screen Each screen contains four icons across the top of the screen in a main menu bar, which include a Run icon, Applicator icon, Feeder icon, and Controller icon. See Figure 32. NOTE If an applicator is connected, an Applicator Connected indicator will be visible in the upper right corner of the screen.
  • Page 23 409-32023 — Use the Enter key to enter fields, activate a highlighted pushbutton, and acknowledge message boxes and save changes. — Use the Cancel key to cancel an operation and exit from some entry fields without saving data. NOTE Pressing the Cancel key repeatedly will exit any field return the user to the Run menu. Feeder Control Keys The Feeder Control keys and indicators are shown in Figure 34.

  • Page 24: Feeder Calibration

    409-32023 3.2. Feeder Calibration 1. Power up the controller. At this point, no applicator is connected and the screen will appear as shown in Figure 35. Feeder Icon Figure 35 2. Use the Right navigation key to move to the Feeder icon on the main menu bar. See Figure 35. 3.

  • Page 25: I/O Interface Settings

    409-32023 Apply and Abort Pushbuttons Feeder Setup Complete Figure 37 3.3. I/O Interface Settings 1. Use the Right navigation key to move to the Precision Controller icon. See Figure 38. 2. To change the “Host Mode”, use the Down navigation arrow to move to the Host Mode field. Press the Enter key to enter the Host Mode selection field.

  • Page 26: Terminal Selection

    409-32023 Trigger1 Dwell Small Up and Down Arrow Keys Figure 39 NOTE Trigger1 dwell is the time period between receiving the Trigger1 signal (air feed from the host terminator) to when the feeder will start its cycle. If you experience timing problems between the terminator cycle and the feeder cycle, this value may be adjusted.
  • Page 27 409-32023 Run Icon Part Number and Serial Number in Applicator Box Figure 40 3. Use the Down navigation key to navigate to the Terminal field. See Figure 41. 4. Press the Enter key to enter the terminal selection field. See Figure 41. Scroll through the list using the Up and Down arrow keys.

  • Page 28: Run

    409-32023 Run Screen Figure 42 3.5. Run Page Data Run Page Wire Chart 1. Use the Up and Down navigation keys to highlight the Wire Chart pushbutton (shown in Figure 42). The Wire Chart screen will be displayed with wire gage and crimp height columns. If the host machine was set to "AMP 3K/5K Coarse Adjust", there will be a coarse adjust column containing the initial setting that is recommended.

  • Page 29: Applicator

    409-32023 2. Press the Enter key. When the Terminal Data pushbutton is activated, a screen similar to the one shown in Figure 43 (Terminal Data screen) will appear. The Up and Down arrow keys can be used to scroll through the data. Data descriptions are given in Figure 44. Serial Number: serial number of the applicator assigned by TE (the serial number is unique for each applicator manufactured by TE)
  • Page 30 409-32023 Applicator Page Wire Chart Selecting the Wire Chart pushbutton will access the screen shown in Figure 46. Selecting the Terminal Data pushbutton will access the screen shown in Figure 46. Data descriptions are given in Figure 44. Wire Chart Screen Terminal Data Screen Figure 46 Tooling Maintenance Page...

  • Page 31: Feeder Data

    409-32023 NOTE The maintenance tools are programmed initially by TE. There are no provisions on the precision controller to edit this data or service the tools when targets are reached. To utilize these advanced features, obtain system III applicator support kit 976700-1;...
  • Page 32 409-32023 The Up and Down navigation keys can be used to navigate down the right side of the screen to any of the outputs. Pressing the Enter key on any of the outputs will cause the output to toggle to the opposite state as depicted by the light next to the output.
  • Page 33 409-32023 Diagnostics Page The diagnostics page is used to test several of the systems on the precision controller. The keyboard, backlight, and one-wire communications can be tested. Use the Up and Down navigation keys to move to the appropriate Test pushbutton, and then use the Enter key to enter or begin the test. See Figure 50. The “Keyboard Test”...

  • Page 34: System Iii Terminal Servo Feeder Operation And Calibration

    409-32023 About Page The “About Page” displays the version of the various software and firmware programs in the unit. This can useful to identify the current versions of software and determine if an upgrade is needed. See Figure 53. Figure 53 4.

  • Page 35: Feeder Calibration

    409-32023 NOTE The feeder may be installed with the terminal strip loaded as shown in Figure 56. Installing Feeder into Applicator Feed Finger in Feed Track Groove (Side-Feed Applicator) Figure 55 Terminal Strip Figure 56 4. Load the applicator (with the feeder attached) into the terminator, and close the guard door. 5.
  • Page 36 409-32023 Feeder Calibration Gage Gage Block Position Figure 57 4. If the feed arm does not enter the gage block as shown in Figure 58, loosen the four latch plate screws as shown in Figure 58, and move the latch plate. Feed Arm Does Not Enter Gage Block Four Latch Plate Screws Figure 58...

  • Page 37: Termination Quality

    409-32023 5. TERMINATION QUALITY Many of the problems that arise during machine usage are the result of improper adjustments rather than machine malfunctions. These problems will generally manifest themselves as one of the poor quality terminations shown in Figure 60. Side-Feed Terminals Terminated Correctly Terminations Unacceptable with Causes...
  • Page 38 409-32023 End-Feed Terminals Terminated Correctly Terminations Unacceptable with Causes (Result of Poorly Adjusted Applicator) Figure 60 (Cont’d) 38 of 41 Rev B Downloaded From Oneyac.com...
  • Page 39 409-32023 Typical Good Termination Wire Brush Protruding From Wire Barrel Insulation Should Extend About Halfway Between Insulation Barrel Crimp and Wire Barrel Crimp Poor Terminations (Result of Improper Machine Adjustments Insulation Does Not Protrude No Brush Wire Protrusion Adjustment Incorrect (Adjust Wire Protrusion) Insulation Does Not Protrude...

  • Page 40: Maintenance

    409-32023 6. MAINTENANCE 6.1. Normal Preventive Maintenance and Lubrication Follow the instructions given in the respective machine manuals. 6.2. System III Feeder Maintenance One Million Cycles of Feeder Operation Every one million cycles of feeder operation, perform the following recommended preventive maintenance procedures: 1.

  • Page 41: Clearing Jammed Terminal Strip

    409-32023 Troubleshoot the feeder as described in Figure 62. PROBLEM PROBABLE CAUSE REMEDY Feeder does not read data correctly. Dirt shorting out applicator memory. Remove memory and clean. Feeder removed before data transfer is Reconnect and allow time for the displayed complete.
  • Page 42 单击下面可查看定价，库存，交付和生命周期等信息 >>TE Connectivity(泰科) Downloaded From Oneyac.com...

This manual is also suitable for:

2161650 series2161655 series

Table of Contents