TE Connectivity FFC Operating Manual

Semi-automatic termination machine

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Operating Manual

FFC Semi-Automatic

Termination Machine

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409-35048

2413730-3

English

PRODUCT INFORMATION 1-800-522-6752

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Page 1 PRODUCT INFORMATION 1-800-522-6752 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.
Page 2 All rights with TE Connectivity (TE) also in case of applications for industrial property ■...
Page 3: Table Of Contents
Description........................18 Layout .............................. 18 4.1.1 Top view ........................19 4.1.2 Side view ........................20 Schematic structure of the FFC Semi-Automatic Termination Machine.......... 21 4.2.1 Head X-Y moving slide ....................22 4.2.2 Waste collection unit ....................23 4.2.3 CCD inspection unit ....................24 4.2.4...
Page 4 5.1.2 Transport instructions (after unpacking) ..............33 5.1.3 Storage, temporary storage ..................33 Commissioning ....................... 34 Installation/Assembly ........................34 6.1.1 FFC Semi-Automatic Termination Machine ..............34 6.1.2 Lifting point ........................35 6.1.3 Electrical ........................35 6.1.4 Compressed air ......................35 Start-up ............................
Page 5 409-35048 7.5.2 Servo motor......................... 68 7.5.3 Camera ........................73 7.5.4 Barcode ........................74 7.5.5 Debugging ........................75 7.5.6 Pressure displacement....................76 Setting interface ..........................77 7.6.1 General settings ......................77 7.6.2 Camera ........................78 7.6.3 Motor ........................... 84 7.6.4 Functions ........................
Page 6 409-35048 12.1 Shutting down the machine ......................107 12.2 Storage ............................107 Disposal ........................108 Drawings, parts lists, circuit diagrams ................109 Replacement and repair ....................109 Rev B 6 of 110...
Page 7: Revision
409-35048 1 Revision Revision process Table 1: Revision process Rev. Date Description Name 28-February, 2024 First edition Henry.REN Updated to standard format & Updated 05-April, 2024 Henry.REN the section 7. Rev B 7 of 110...
Page 8: Introduction
Tyco Electronics Shanghai Co., Ltd. disclaims all liability for any damage attributed to failure to observe instructions on the FFC Semi-Automatic Termination Machine or in this operating manual. The manufacturer is not liable for any damage attributed to changes or modifications to the FFC semi-automatic termination machine not mentioned in this operating manual.
Page 9: Signs And Symbols Used In This Document
Special safety instructions are provided where necessary. See section 3. Abbreviations Table 2: Abbreviations Abbreviations Meaning Product material No. TE Connectivity Field Service Engineer Force vs Distance Measurement Flexible flat cable Flexible printed cable Foil Flexible sheet Terminal FFC terminal Automatic optical inspection mechanism Rev B 9 of 110...
Page 10: General Notes On Safety
Intended use The FFC Semi-Automatic Termination Machine is a semi-automatic terminal press that can be equipped with product-specific press-fit tools for processing FFC terminals. Information on press-fit tools can be found in the relevant operating manual. Operational environment The machine must only be used in a dry and dust-free environment.
Page 11: Safety Devices
However, certain safety precautions must be taken by operators, maintenance and repair personnel to prevent personal injury and damage to the machine. The FFC Semi-Automatic Termination Machine has the following protective and safety devices: Emergency Stop switches ■ Protective Door switches ■...
Page 12: Protective Door Switches
409-35048 3.3.2 Protective door switches The FFC Semi-Automatic Termination Machine is equipped with a safety system which prevents the operator from accessing the machine while the machine is running. The system is equipped with two safety guards at the front side, and one protective door at the upper and lower parts of the rear area, respectively. The...
Page 13: Safety Measures
Safety measures 3.5.1 General The FFC Semi-Automatic Termination Machine may be used only for its intended purpose. The machine must only be used by trained and authorized personnel. The responsibilities of personnel for operation, setting, maintenance and repair must be clearly defined by the owner/operator of the machine and observed.
Page 14: Safety Measures For Maintenance
The disconnected components must first be checked for absence of power, then earthed and short-circuited, and adjacent live parts insulated. The electrical equipment of the FFC Semi-Automatic Termination Machine must be regularly tested. Defects, e.g. loose connections or scorched cables must be remedied immediately.
Page 15: Personnel Qualification
409-35048 3.5.6 Personnel qualification The operator is responsible for ensuring that every person working with the machine has been familiar with the contents of this operating manual. The operator is also responsible for the training of operating personnel, which must include the following: Intended use ■...
Page 16: Warnings
409-35048 Warnings NOTE Keep all decals clean and legible. Replace them when DANGER necessary. Inspect the tool and jaws/dies before each use. DANGER Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby ELECTRIC SHOCK HAZARD personnel.
Page 17: Safety Signs (Type-Specific)
(reversible hearing loss after an extended period) and deafness following prolonged exposure (irreversible hearing loss). Read the operating manual The described object (FFC Semi-Automatic Termination Machine) must only be used after the user has read the operating manual. Safety gloves must be worn If safety gloves must be worn due to a risk of injury, this must be indicated.
Page 18: Description
409-35048 4 Description The FFC Semi-Automatic Termination Machine consists of the following modules. Layout Figure 3: Front view Table 5: Front of the FFC Semi-Automatic Termination Machine Item Name Item Name Buttons and Emergency Stop Operator panel + screen switch...
Page 19: Top View
409-35048 4.1.1 Top view Figure 4: Machine top view Rev B 19 of 110...
Page 20: Side View
409-35048 4.1.2 Side view Figure 5: Machine side view Rev B 20 of 110...
Page 21: Schematic Structure Of The Ffc Semi-Automatic Termination Machine
409-35048 Schematic structure of the FFC Semi-Automatic Termination Machine Figure 6: Schematic structure Table 6: Schematic structure Item Name Item Name Head X-Y moving slide Waste collection unit CCD inspection unit + Foil front Terminal crimping unit bezel Terminal feeding unit...
Page 22: Head X-Y Moving Slide
409-35048 4.2.1 Head X-Y moving slide Figure 7: Moving slide Table 7: Foil moving slide Name Function X-axis motor X-direction slide drive Cable drag chain Protecting the moving cable on the slide X-axis screw rod assembly X-direction movement mechanism Y-axis motor Y-direction slide drive Y-axis screw rod assembly Y-direction movement mechanism...
Page 23: Waste Collection Unit
409-35048 4.2.2 Waste collection unit Figure 8: Waste collection unit Table 8: Waste collection unit Name Function Waste collection pipe For feeding the cut-off waste into the waste bin via this pipe Waste bin For storage of waste Waste bin in-place inspection For confirmation of the presence of the waste bin Rev B...
Page 24: Ccd Inspection Unit
409-35048 4.2.3 CCD inspection unit Figure 9: CCD inspection unit Table 9: CCD inspection unit Name Function CCD camera Image capturing device Lens Optical device Top light source Light source for the top of the product Bottom light source Light source for the bottom of the product Bracket Bottom light source and light shield...
Page 25: Terminal Crimping Unit
409-35048 4.2.4 Terminal crimping unit Figure 10: Terminal crimping unit Table 10: Terminal crimping unit Name Function Crimping motor Crimping driver CRIMPER unit Forming blade and pressure sensor unit ANVIL unit Bottom blade and crimping height adjustment unit Crimping height detection Magnetic scale and reading head for mechanism checking the crimping height...
Page 26: Terminal Feeding Unit
409-35048 4.2.5 Terminal feeding unit Figure 11: Terminal feeding unit Table 11: Terminal feeding unit Name Function Feeding ratchet Feeding with ratchet Terminal in-feed channel Terminal transfer channel Ratchet locking cylinder Locking ratchet's snap-in position Strap positioning aid Hand-pressed positioning pins Sensor for pitch inspection Positioning check of strap feeding holes...
Page 27: Active Reel Release Mechanism
Take-up motor and reel support Take-up motor Take-up motor for reeling in tape Take-up reel Tape storage Reel clip For clipping the reel and the materials in the reel Terminal reel Reel for organizing FFC terminals Rev B 27 of 110...
Page 28: Control Elements
409-35048 Control Elements Figure 13: Control elements Table 13: Control elements Name Name Emergency Stop switches Control button Air triplex Main Power Switch Touch screen Rev B 28 of 110...
Page 29: Operator Panel
409-35048 4.3.1 Operator Panel The machine is operated using a touch screen with push buttons and an Emergency Stop switch on the upper left side. Figure 14: Operator Panel 4.3.2 Main Switch Starts the machine Figure 15: Main switch Rev B 29 of 110...
Page 30: Technical Data
409-35048 Technical data 4.4.1 Rating plate Figure 16: Rating plate 4.4.2 Machine data Table 14: Machine data Date Value Unit Dimensions (net) 1300 x 860 x 1450 (W x D x H) Dimensions (packaging) 1850 x 1050 x 2400 (W x D x H) Weight (net) about 380 Weight (with packaging)
Page 31: Electrical Requirements
409-35048 4.4.5 Electrical requirements Electrical Data Table 17: Electrical Data Date Value Unit Supply voltage V AC System frequency Phases Phase Power consumption Air pressure 600 - 800 Air consumption Litre/min Rev B 31 of 110...
Page 32: Delivery
409-35048 5 Delivery Internal transport The machine can be transported packed by forklift truck. After unpacking, it will be necessary to use transport aids. Observe the information on reasonable loads. NOTE The machine was packed and secured for safe transport in the TE plant. Unpacking, Setup and first installation have to be done by a FSE from TE.
Page 33: Transport Instructions (After Unpacking)
409-35048 5.1.2 Transport instructions (after unpacking) The weight of the machine is about 380 kg. The machine must be transported with suitable fork lifter. The fork lifter must be equipped with forks with a minimum length of 1.6 meters.  Lift the machine at the marked points (operator side / centered) ...
Page 34: Commissioning
 The customer assumes the risk of installing other software that may affect the network of the machine (e.g., anti-virus software with firewalls, VPN clients, etc.) 6.1.1 FFC Semi-Automatic Termination Machine Preconditions/requirements for the site of installation  The machine base is marked with lifting points for handling by forklift truck or pallet truck.
Page 35: Lifting Point
409-35048 6.1.2 Lifting point Figure 17: Lifting point Lifting point 6.1.3 Electrical Preconditions/requirements for electrical supply NOTE The machine is electrically designed to comply with EN 60204 (for industrial equipment). The power supply must be suitable for industrial equipment and comply with all requirements of EN 60204-1/EC 60204-1. 6.1.4 Compressed air Requirements for compressed air source The compressed air source is required to supply air through a flow control valve.
Page 36: Start-Up
Press the zero button to put the machine into standby mode after a short reset action;  Set the machine;  Select the operating program. The FFC Semi-Automatic Termination Machine is now ready for use. Rev B 36 of 110...
Page 37: Machine Control
After completing the work, the machine must be cleaned and, if necessary, serviced and lubricated. Switching on Figure 18: Main switch (example)  on the FFC Semi-Automatic Termination Machine with the main switch by Switch dialing from 0 to 1. Figure 19: Triplex ...
Page 38: Introduction To The Software Interface
409-35048 Introduction to the software interface Figure 20: Boot screen  Double-click FFC.exe shown in the red box after the machine starts up and the desktop is displayed to enter the login interface. Rev B 38 of 110...
Page 39: Interface Framework
409-35048 7.2.1 Interface framework Figure 21: Default interface Top status bar: A status bar that displays alarm messages that can be clicked on to provide more information about the error. Left menu: A menu of page buttons that can be clicked on to display different functional interfaces. Bottom menu: A menu of shortcut buttons that can be clicked on to enable different functions.
Page 40: Login Interface
409-35048 Instructions for use of shortcut buttons: Table 20: Instructions for use of shortcut buttons Function Icons Instructions for Use Unavailability Buttons  Click the light to turn it on; Light None and click it again to turn it off. Top up the positioning pin, press and hold the ratchet ...
Page 41: User Information
409-35048 Figure 22: Login interface Click on Login and enter your account and password to log in to the system. 7.2.3 User information Figure 23: User information Check √ Change Password, input the old password and new password in the input boxes displayed, and click on OK to finish.
Page 42: User Management
409-35048 7.2.4 User management Figure 24: User management Post: the specified post level, e.g., Engineer, Operator, etc. User: the login name. Password: the login password. Rev B 42 of 110...
Page 43: Permission Management
409-35048 7.2.5 Permission management Figure 25: Permission management As shown in the Figure 25 above, you can select the post information from the post drop-down box, and the permissions and values below will show the current selection; the black square in the Value column indicates that the post has the permission.
Page 44: Job Management
409-35048 7.2.6 Job Management Figure 26: Job Management This interface allows you to create, edit and delete the settings of the related posts. If you want to set up automatic logout, you can check the "Auto Logout" check box. Rev B 44 of 110...
Page 45: Production Interface
409-35048 Production interface 7.3.1 Page 1 Each part of the interface is shown in the below. Figure 27 Figure 27: Page 1 A: Program running status and formula selection. B: Test result. C: FVD curve. D: Image real-time display. Curve Zoom Out: Press and hold the left mouse button, and slide from right to left. Curve Zoom in: Press and hold the left mouse button, and slide from left to right.
Page 46 409-35048 Figure 29: Formula button You need to select a formula, so click on the Formula button. 7.3.2 Page 2 Figure 30: Page 2 Rev B 46 of 110...
Page 47: Formula Interface
409-35048 Formula interface The following parameters need to be set when the camera is used for the first time or when the camera is replaced. After the settings are completed, the default can be selected for Formal Production. 7.4.1 Set up of the terminal Camera gain and exposure time should be adjusted according to the sharpness of the object presented in the camera.
Page 48 409-35048 Figure 33: Formula prompt The copied formula will have the serial number added at the end of the formula. Click on OK and the formula copy is completed. Figure 34: Formula prompt [Delete Formula]: Select the formula to be deleted and click to delete it. Figure 35:Deleting Formula A pop-up box will appear;...
Page 49 409-35048 Figure 36: Formula prompt Continue to click on OK and the formula will be deleted successfully. Figure 37: Formula prompt [Block X Position]: The centerline of the first copper tape to the right of the first block is the 0 coordinate in the X direction, and the X position of the other blocks is noted as the distance between the centerline of the first copper tape to the right and the 0 coordinate.
Page 50 409-35048 [Copper Pitch]: Pitch of copper tape in this block. [Quantity of Copper Tapes]: Quantity of copper tapes in this block. [Clear Space Width on Left Side]: The distance between the left edge of the block's Foil and the left edge of the leftmost copper tape.
Page 51: Crimping Height And Crimping Force
409-35048 7.4.2 Crimping height and crimping force Crimping height and crimping height tolerance are set according to the actual requirements. Crimping height: the height for terminal crimping. Crimping height tolerance: the range of plus or minus error of crimping height. Maximum crimping force: maximum pressure to crimp the terminal.
Page 52: Position Correction
409-35048 7.4.3 Position correction Figure 42: Position correction [Camera Gain]: recommended value of 0.7 [Exposure Time]: ranging from 0 to 15000 [Processing Mode]: General by default, not required to select [ROI]: Select the copper tape, and two boxes are required Rev B 52 of 110...
Page 53 409-35048 Figure 43: Positioning The (lower) top side of the box should be as close to the black bar as possible, while leaving a distance from the top (lower) edge so that it does not overlap the black bar. The right sides of all boxes should not exceed the red line. Choose the position where the change in the copper strip occurs, if the copper has a change in width.
Page 54 409-35048 Suggestions for several typical Foil placement areas are listed in the below: Table 21 Table 21: Foil placement areas FPC front side FPC back side Foil top (Blue box) For light colored copper For light colored copper foils, For dark colored copper foils, place the top of the place the top of the Foil in the foils, place the top of the...
Page 55 409-35048 Figure 46: ROI Editor  Delete: To delete a certain area, click on the blue box, and after the blue box becomes green, click on the Delete button to delete the selected area. In the editing state, the blue box cannot be selected and you need to turn off editing by clicking on the Edit button.
Page 56 409-35048  Clear: Click on the Clear button to delete all the box-selected areas.  Zoom In/Out Image: In the ROI selection dialog box, zoom in or out the image with the mouse wheel.  Move Image: In the ROI selection dialog box, press and hold the right mouse button to drag the image.
Page 57 [Angle Range]: Set according to the product [Substrate Camera Gain]: Recommended value of 0.3 [Substrate Exposure Time]: Ranging from 0 to 15000 [Substrate ROI]: To select the substrate, you can use 1 box (such as FFC products) or 2 boxes (such as FPC products) Rev B...
Page 58 409-35048 Figure 50: Substrate ROI The right sides of the boxes should extend beyond the red line. The boxes can only be within the white bar area The Foil must be contained from the left sides [Substrate Threshold]: Figure 51: Substrate Threshold [Positional Deviation]: 1 mm by default.
Page 59 409-35048 Figure 52: Positional Deviation Figure 53: Positional Deviation Rev B 59 of 110...
Page 60: Visual Inspection
409-35048 7.4.4 Visual inspection Visual inspection contains multiple inspection items. Each inspection item can be set and enabled separately. Since the inspection points used in multiple inspection items are duplicated, the parameters can be quickly set by using the Copy and Paste buttons on different interfaces. 1.
Page 61 409-35048 Figure 55: ROI selection for P1.D The Figure 55 above shows a sample of ROI selection for P1.D. Figure 56: sample P1 threshold setting This piece is considered to be the overall width of what is detected. Above is a sample P1 threshold setting. The white area in the above image forms a piece that is set as a block.
Page 62 409-35048 2. Position Y inspection Position Y inspection takes the length of the substrate exposed after crimping the terminals to ensure that the terminals and substrates have enough contact surface. The principle is to take the value of the distance between the P1 and the upper edge of the substrate. Figure 57: Position Y inspection Rev B 62 of 110...
Page 63 409-35048 Figure 58: sample of substrate position ROI selection The Figure 58 above is a sample of substrate position ROI selection. Figure 59: substrate threshold setting The Figure 59 above is a sample of substrate threshold setting. Rev B 63 of 110...
Page 64 409-35048 3. X1/X2 position inspection It checks whether the terminal coincides with the pin position of the substrate. It checks the X1 position or X2 position to detect the value of concentric deviation between the center of the terminal head/middle and the center of the copper tape.
Page 65 409-35048 4. Deformation inspection It checks whether the terminals are twisted or deformed. The principle is to check whether the width of the S position is within the set inspection range. Figure 61: Deformation inspection Rev B 65 of 110...
Page 66 409-35048 5. Pitch inspection, It checks whether the spacing between the terminals complies with the formula. The principle is to check the distance value between the center of the P1 point of each terminal and the P1 point of the previous terminal.
Page 67 409-35048 6. Terminal presence or absence The presence or absence of a terminal is determined by detecting whether the head of the terminal and the center of the terminal are present at the same time. Figure 63: Terminal presence or absence Rev B 67 of 110...
Page 68: Manual Interface
409-35048 Manual interface The following parameters need to be set when the camera is used for the first time or when the camera is replaced. After the settings are completed, the default can be selected for Formal Production. 7.5.1 Cylinder This is the interface for manual operation of the cylinder.
Page 69 409-35048 [Origin Indicator]: Green indicates that return to origin has been completed and gray indicates that return to origin is not completed or it is returning to the origin. [Locking Indicator]: Red indicates that the motor is in a locked state and it is necessary to check whether there is an interlocking condition that affects the motor's movement, and gray indicates that the motor is not locked and can be moved.
Page 70 409-35048 [Go to Relative Position]: When clicked, it will move to the value in the relative positioning and differentiate the direction. Current motor is in power-off state Current motor is in power-up state Returned to origin Not returned to origin ...
Page 71 409-35048  X-axis motor Figure 70: X-axis motor  Y-axis motor Figure 71: Y-axis motor Rev B 71 of 110...
Page 72 409-35048  Z-axis motor Figure 72: Z-axis motor Rev B 72 of 110...
Page 73: Camera
409-35048 7.5.3 Camera This is the Camera View page, where you can operate the movement of the camera and observe the status of the settings. Go to correction position; Go to inspection position; Trigger correction; Trigger inspection; Save picture. Figure 73: Camera Rev B 73 of 110...
Page 74: Barcode
409-35048 7.5.4 Barcode [Barcode]: After aligning the reader to the barcode, click on it to read the code and the barcode information will be displayed in the barcode area. [Compare String]: Input the string to be compared. [Compare Starting Position]: Input the starting position character to be compared. Figure 74: Barcode Rev B 74 of 110...
Page 75: Debugging
409-35048 7.5.5 Debugging This is a developer interface for developers to debug the device. It supports visual query of PLC operation status, including current motor commands, host computer commands, automatic steps, etc. Figure 75: Debugging Rev B 75 of 110...
Page 76: Pressure Displacement
409-35048 7.5.6 Pressure displacement It monitors the FVD curve, where the contact force is the critical force setpoint, beyond which the collection of points begins. [X Null Offset]: For setting the null offset of the displacement channel. [Clearance]: For setting the null offset of the pressure channel. [Number of Acquisition Points]: The Channel sampling rate is 5KHZ.
Page 77: Setting Interface
409-35048 Setting interface The following parameters need to be set when the camera is used for the first time or when the camera is replaced. After the settings are completed, the default can be selected for Formal Production. 7.6.1 General settings Figure 77: General settings [Language]: After checking the language, restart the software to take effect.
Page 78: Camera
409-35048 7.6.2 Camera Figure 78: Camera After clicking on the Camera Settings, just keep the factory settings. The description of each parameter is as follows: [Camera Address]: It is fixed by software and cannot be modified. [Camera Gain]: If the brightness of visual photography is not suitable, you can adjust the value appropriately.
Page 79 409-35048 Figure 79: Image correction After clicking on Image Correction, enter the specifications and dimensions of the calibration plate and the number of corner points, and then click on the Set button. Note on the number of corner points: If the calibration plate has 20 x 16 black-and-white grids, the number of corners is 19 x 15.
Page 80 409-35048 Figure 81: Size correction Rev B 80 of 110...
Page 81 409-35048 Click on Size Correction to display a prompt box showing "Please put in calibration plate," put the calibration plate into the center of the field of view. Figure 82: calibration plate When a red and green mark appears on the calibration plate, click on the Set button to complete the size correction.
Page 82 409-35048 Figure 84: XROI Figure 85: XROI Rev B 82 of 110...
Page 83 409-35048 [YROI]: Select the specific horizontal prism as shown in the Figure 86 below, with the center line of the prism as the Y zero point. Figure 86: YROI Figure 87: YROI Rev B 83 of 110...
Page 84: Motor
409-35048 After all the settings are completed, click on the Settings and Calibration buttons in the lower right corner. Now, the camera calibration is complete. Figure 88: Settings 7.6.3 Motor There are four servo motor setup pages, and each motor page is divided into areas for system parameters and for user parameters.
Page 85 409-35048 Figure 90: X motor Figure 91: Y motor Rev B 85 of 110...
Page 86 409-35048 Figure 92: Z motor Rev B 86 of 110...
Page 87: Functions
409-35048 7.6.4 Functions Mode column: 1. If all the boxes are unchecked, it is the in normal trial production mode. 2. If you only check the box of tune-up, it switches to the tune-up mode (one time of idle operation without material).
Page 88: Timeout
409-35048 7.6.5 Timeout In general, keep the default settings. Figure 94: Timeout Rev B 88 of 110...
Page 89: General Parameters
409-35048 7.6.6 General parameters It is necessary to box-select the X and Y coordinate area, and at the same time, you can set the offset value for different products. Figure 95: General parameters [Distance between crimp position and visual Y-axis]: The value needs to be increased as the distance increases.
Page 90: Product Parameters
409-35048 [Y inspection offset]: You need to move the topmost part of the terminal to the topmost white area. In the field of view, the terminal needs to be moved up and this value needs to be increased. Figure 97: Y inspection offset [Detection length]: Maximum length in X direction that the clamp can place the Foil.
Page 91: Hmi Parameters
409-35048 7.6.8 HMI parameters It is necessary to box-select the X and Y coordinate area, and at the same time, you can set the offset value for different products. Figure 99: HMI Parameters 7.6.9 MES If necessary, please contact the sales team. Rev B 91 of 110...
Page 92: Statistics Interface
409-35048 Statistics interface The following parameters need to be set when the camera is used for the first time or when the camera is replaced. After the settings are completed, the default can be selected for Formal Production. 7.7.1 Lifetime Figure 100: Service life The speed of fatigue test is the automatic speed of Z-axis.
Page 93: Alarms
409-35048 7.7.2 Alarms Alarm category: red font Warning category: yellow font Tip category: white font Figure 102: Alarms 7.7.3 Operating log All operating logs from the time the software was turned on are shown here. When the software is turned off, the operating log is cleared.
Page 94: Io List
409-35048 7.7.4 IO list X00-X31 and X32-X47 are DI lists. They show green when there is a signal. They show gray when there is no signal. Y00-Y31 and Y32-Y47 are DI lists. They show green when there is output. They show gray when there is no output.
Page 95: System Interface
409-35048 System interface Exit: Click on Exit and the FFC software will close. Power Off: Click on Power Off and the computer will be powered off. Reboot: Click on Reboot and the computer will reboot. Figure 105: System interface ...
Page 96: New Product Commissioning
409-35048 8 New Product Commissioning The proposed commissioning process for a new product is as follows:  Call the prepared production formula, set the equipment to manual mode and then click on the [Start] button to operate in CYCLE mode step by step. ...
Page 97: Troubleshooting
409-35048 9 Troubleshooting NOTE If the machine is in the state of reporting error:  the orange signal light flashes or the buzzer sounds.  The machine stops and the reset button (yellow) lights up.  An Error message is displayed on the HMI. General troubleshooting information ...
Page 98: Error Message
409-35048 9.2.1 Error message Explanation: The content in () represents the sensor code. For example, ratchet feed error (E1002): E1002 means that the sensor E1002 may be faulty and the code is applied to the sensor in the form of a line number. ...
Page 99 409-35048  SM102 Crimp: Motor [Positioning Abnormal]: Motor positioning command was executed incorrectly.  EA100 Y-axis: Motor [OFF in progress]: Motor is not enabled.  EA100 Y-axis: Motor [Alarm in progress]: Motor has an alarm.  EA100 Y-axis: Motor [Positioning Abnormal]: Motor positioning command was executed incorrectly.
Page 100: Alarm Message
409-35048  Maximum Press-Fit Force Failed: Failure of the maximum press-fit force is detected.  Waveform Monitor Alarm: There is an alarm (Kistler) on the waveform monitor. 9.2.2 Alarm message  Not Return to Origin: Return to Origin is not completed. This message also appears in the following cases: 1.
Page 101 409-35048  SM101 X-axis transfer: Mark inspection-reverse [Manual-Automatic Inconsistency]: The cylinder is operated in the manual screen. Please restore the cylinder status.  SM101 X-axis transfer: target Mark inspection [Manual-Automatic Inconsistency]: The cylinder is operated in the manual screen. Please restore the cylinder status. ...
Page 102: Maintenance
409-35048  Barcode reading timeout [Warning]: The barcode is not read after the specified time.  No valid barcode was read [Warning]: The barcode read does not match the formula setting. CAUTION Be cautious of hand injuries! Extremities may be crushed during accidental movement of electrical components. ...
Page 103: Inspection And Maintenance Items
409-35048 10.1 Inspection and maintenance items Table 22: Inspection and maintenance items Type of Object Maintenance Contents Maintenance Daily Equipment Clean external surfaces with flexible cleaner and soft Maintenance surfaces rags. Waste bag Empty the waste bag and put the waste into the corresponding waste container.
Page 104: Empty The Waste Bin
409-35048 10.1.2 Empty the waste bin Figure 107: waste bin 10.1.3 Empty the paper tape reel Figure 108: paper tape reel Rev B 104 of 110...
Page 105: Grease Injection Port
409-35048 10.1.4 Grease injection port Figure 109: Grease injection port 10.1.5 Electrical cabinet air intake fan Figure 110: Electrical cabinet air intake fan 10.2 Maintenance work Maintenance may only be carried out by specially trained personnel from the machine manufacturer (FSE for TE) or by personnel with specialized operator training! The maintenance personnel must: know the functions and operations of the equipment and must know the safety installations of it...
Page 106: Spare And Wearing Parts
409-35048 Ensure that all safety installations are mounted and functioning. ■ Functional check of the equipment. ■ Release the equipment for production after the functional check has indeed been completed. ■ 11 Spare and wearing parts See the Table 23 & Table 24 below for a list of parts: Table 23: Spare parts list Spare parts list Part Number...
Page 107: Shutting Down The Machine
409-35048 Table 24: List of wearing parts List of wearing parts Part Number Description Quantity 8-2439352-0 Ratchet for NANO MQS 4-2413734-5 Ratchet reset spring 2-2413732-1 Form cutter 1-2413732-7 Shuffle block 6-2439353-7 Shuffle seat guide 5-2439352-1 Eccentric shaft 8-2413732-9 Sliding block for eccentric shaft 4-2439352-3 Cutting knives 3-2413732-4...
Page 108: Disposal
This waste must be taken to a suitable recycling facility. WEEE Directive In accordance with the WEEE Directive, TE Connectivity supports recycling of the waste of electrical and electronic equipment. Relevant information can be found on the following website: http://www.tycoelectronics.com/customersupport/rohssupportcenter/...
Page 109: Drawings, Parts Lists, Circuit Diagrams
409-35048 14 Drawings, parts lists, circuit diagrams See the appendix (it will be sent with the machine, or please contact us for more information). 15 Replacement and repair Stock and control a complete inventory to prevent lost time when replacement of parts is necessary. Order or return parts through your TE representative, or go to TE.com and click the Shop TE Store link at the top of...
Page 110 409-35048 Application Tooling Rev B 110 of 110...