0623003000

Hawk Flat Cable Termination Machine “HAWK” FLAT CABLE TERMINATION MACHINE Operation Manual 62300-2900 "Hawk" F.F.C. Terminator 62300-2950 "Hawk" F.F.C. Terminator 62300-3000 "Hawk" Ribbon Cable Term. 62300-5200 " Hawk" F.F.C. Terminator W/Breakoff 62300-5300 "Hawk" R.C. Terminator W/Breakoff For C-Grid® SL IDT Connector, 70400 Series Description Operation Maintenance Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 1 of 48 Hawk Flat Cable Termination Machine Safety Warnings and Information Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. DANGER: DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. WARNING: WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury. WARNING Always wear proper eye protection when Operating or servicing this machine. Failure to wear eye protection could result in serious eye injury from flying debris. WARNING Never wear clothing or jewelery that is loose or That Could potentially hang into the equipement And get caught. Failure to observe this warning could result in Severe Injury or death. WARNING Never operate, service, install, or adjust this Machine without proper instruction and without first reading and understanding the instructions in this manual and all applicable press and/or wire processing machine manuals. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 WARNING Excessive noise levels. Always wear proper ear protection when Operating or servicing this machine. WARNING Never install or service this machine while connected to any electrical power source. Disconnect power by unplugging the machine from its power source. Failure to observe this warning could result In severe injury or death. WARNING Never lift this machine without the aid of mechanicall lifting devices. Failure to observe these precautions may result in severe back, other injuries, or property damage. UNCONTROLLED COPY Page 2 of 48 Hawk Flat Cable Termination Machine WARNING WARNING Never use this machine without guards or safety devices that are intended to prevent hands from remaining in the termination orfeed areas. Failure to observe this warning could result in Severe injury or death. Do not use compressed air to clean the equipment. The forces created by compressed air can force debris into the tool. Failure to observe these precautions may result in injury or property damage. CAUTION Never perform any service or maintenance other than as described in this manual. Never modify, alter or misuse the equipment Molex crimp specifications are valid only when used with Molex terminals and tooling. Failure to observe this precaution may result in injury and property damage. Tooling Technical Assistance Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group. Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global). This assistance is limited to the operation and set-up of a customer’s Molex Terminator Machine. Questions with regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service Representative. When calling for service on the machine it is recommended to have the following: a copy of the Tooling Manual, the Specific Specification Sheet and a person familiar with the machine should be present. The following information is also recommended to supply: 1.Customer name 2.Customer address 3.Person to contact such as (name, title, e-mail, and telephone number) 4.Machine order number (Lease number also if applicable) 5.Serial number (Lease number also if applicable) 6.Molex Connector product order number 7.Urgency of request 8.Nature of problem Molex Application Tooling Group 2200 Wellington Court Lisle, IL 60532, USA Tel: +1 (630) 969-4550 Fax:+1 (630) 505-0049 Visit our Web site at http://www.molex.com Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 3 of 48 Hawk Flat Cable Termination Machine Table of Contents Contents “HAWK” FLAT CABLE TERMINATION MACHINE .................................................................................................................................. 1 Safety Warnings and Information ............................................................................................................................................................ 2 Tooling Technical Assistance .................................................................................................................................................................. 3 Table of Contents .................................................................................................................................................................................... 4 Section 1.................................................................................................................................................................................................. 6 General Description............................................................................................................................................................................. 6 Principal Mechanical Parts of the Flat Cable Termination Machine .................................................................................................... 7 1.1 Description ............................................................................................................................................................................. 8 1.2 Features ................................................................................................................................................................................. 8 1.3 Technical Specification .......................................................................................................................................................... 8 1.4 Delivery Check ....................................................................................................................................................................... 8 1.5 Tools ...................................................................................................................................................................................... 9 1.6 Installation .............................................................................................................................................................................. 9 1.7 Changing Tooling ................................................................................................................................................................. 10 Section 2................................................................................................................................................................................................ 11 Set-Up and Operation ....................................................................................................................................................................... 11 2.1 Setting Up ............................................................................................................................................................................ 12 2.2 Setting Batch Size ................................................................................................................................................................ 14 2.3 Setting Breakoff Strokes ...................................................................................................................................................... 14 2.4 Operation ............................................................................................................................................................................. 14 Section 3................................................................................................................................................................................................ 17 3.1 Maintenance......................................................................................................................................................................... 18 3.2 Perishable Parts ................................................................................................................................................................... 19 3.3 Spare Parts .......................................................................................................................................................................... 19 3.4 Troubleshooting ................................................................................................................................................................... 19 3.5 Fault Message Procedure .................................................................................................................................................... 20 Section 4................................................................................................................................................................................................ 21 4.1 Description ........................................................................................................................................................................... 22 4.2 Technical Specifications....................................................................................................................................................... 22 4.3 Installation and Removal ...................................................................................................................................................... 22 4.4 Operation ............................................................................................................................................................................. 23 Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 4 of 48 Hawk Flat Cable Termination Machine Section 5................................................................................................................................................................................................ 24 5.1 62300-2900 Parts List and Assembly Drawings................................................................................................................... 26 62300-2950 Parts List and Assembly Drawings ................................................................................................................................ 27 62300-3000 Parts List and Assembly Drawings ................................................................................................................................ 28 62300-5200 and 62300-5300 Parts List and Assembly Drawings..................................................................................................... 29 62300-2600 Parts List and Assembly Drawings ................................................................................................................................ 30 62300-3400 Parts List and Assembly Drawings ................................................................................................................................ 32 62300-3500 Parts List and Assembly Drawings ................................................................................................................................ 34 62300-4700 Parts List and Assembly Drawings ................................................................................................................................ 36 62300-5000 and 62300-5100 Parts List and Assembly Drawings..................................................................................................... 37 5.2. Electric Controls ................................................................................................................................................................... 38 5.3 Pneumatic Diagram.............................................................................................................................................................. 43 Section 6................................................................................................................................................................................................ 44 Glossary of Terms ............................................................................................................................................................................. 44 Section 7................................................................................................................................................................................................ 45 7.1 I.D.T. Termination Process Control ...................................................................................................................................... 46 7.2 Process Capability .............................................................................................................................................................. 46 7.3 Production ............................................................................................................................................................................ 47 Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 5 of 48 Hawk Flat Cable Termination Machine Section 1 General Description 1.1. Description 1.2. Features 1.3. Technical Specifications 1.4. Delivery Check 1.5. Tools 1.6. Installation 1.7. Changing Tooling Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 6 of 48 Hawk Flat Cable Termination Machine Principal Mechanical Parts of the Flat Cable Termination Machine FILTER REGULATOR OPERATION INTERFACE POWER ON BUTOON EMERGENCY STOP BUTTON TERMINATION AREA SHUTTLE CYLINDER SINGLE TUBE FEEDER FOOT PEDAL ASSEMBLY Figure 1-1 Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 7 of 48 Hawk Flat Cable Termination Machine General Description % 1.1 Description The 62300-2900 flat flex cable termination machine was developed to assemble .100 S.L. flat flex cable harnesses. The 62300-2950 is the same as the 62300-2900 except no electrical or pneumatic controls are installed. The 62300-3000 ribbon cable termination machine was developed to assemble .100 S.L. IDT ribbon cable assemblies. The 62300-5200 and the 62300-5300 are the same as the 62300-2900 and the 62300-3000 respectively except these have the carrier breakoff option. An operator loads a tube containing preloaded connectors (70430,70431 or 40556 series for FFC, or 70400 and 70475 for SL) from 2 - 25 circuits (See note below). As each connector assembly is terminated, the terminals are inserted, then the machine automatically loads a new connector into the terminating nest, pushing out the previously loaded connector. The operator then removes the harness from the termination area and inserts the carrier strip into the strip breakoff slot and bends the carrier strip down to break it off. To process another harness, the operator loads a cable, then depresses the foot pedal. The machine then terminates that cable and indexes another connector into position, and so on. This machine is ideally suited for mid- volume, semiautomatic applications. % % % % % % A rugged, sealed operator interface with a 24-key tactile feedback keypad for data entry, and a 20character 2-line displayfor displaying batch count, fault messages, etc. Operator setable batch counter. Totally enclosed for operator safety. Easily attached option available for automatic carrier strip breakoff. Accepts 25 in. (635 mm) and 564 mm (22.2 in.) tubes. "CE" Certified. 1.3 Technical Specification Dimensions Width: 945 mm (37.25 in.) Depth: 914 mm (36.0 in.) Height: 494 mm (19.5 in.) (without feet) Weight 48.1kg (103lbs) Unpacked Power Requirements Voltage: 110 VAC or 220 VAC 50/60 Hz Current: 1 A @ 110 V or 220 V Pneumatics Pressure: 5 BAR (80psig) min. Consumption: 14L/min (.5 SCFM) Rate Up to 750 connectors per hour depending on operator skill 1.4 Delivery Check NOTE: 2 circuit connectors may be processed in these machines but only in chains of two (2) or more. It is also recommended that 3 circuit connectors be run in chains of two (2) or more to avoid feed jams. An option is available that automatically breaks off the carrier strip as it comes out of the termination head. This option is available factory installed or it can be easily installed or removed in the field. 1.2 Features % % Remove the top and sides of the crate. Then remove the screws that mount the machine to the skid. Check to see that following items are included in this package: Qty. 62300-XX00 Termination Machine 1 63800-8394 Foot Pedal Assembly 1 11-32-1659 Power Cord 1 11-31-5302 Nest Cleaning Tool 1 63600-0785 Leveling Feet 4 62300-2999 Instruction Manual 1 Automatic loading of termination nest. Automatic insertion of terminals. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 8 of 48 Hawk Flat Cable Termination Machine 1.5 Tools Power Connection The following tools will be needed for setup and adjustment of the Hawk termination machine. Ε Ε Ε Ε Ε 1.6 Hex Wrench Set (inch) Large and small straight screwdriver Small Crescent Wrench Pliers (Needle nose) Eye Loupe 5X 110VAC Hookup This terminator normally comes from the factory set for 110VAC. A power cord is supplied for 110VAC service. To use terminator for 110VAC, plug the power cord into the socket in the power inlet module in the back of the control enclosure (See Figure 1-2), then plug the other end into a grounded outlet. POWER INLET Installation WARNING: The Molex Hawk terminator weights 48kg (103 lbs.) and is NOT intended to be lifted by an individual. The guarding or connector load assemblies are not attached to provide support for lifting purposes. Mechanical lifting devices should be used from below the unit. A person lifting this machine could sustain severe back or other injuries. Care should be taken at all times. An electrical, hydraulic or mechanical lift should be used to lift this terminator. FILTERREGULATOR PRESSURE GAUGE FOOT SWITCH PLUG POWER INLET MODULE Figure 1-2 Foot Pedal Connect the 4-pin Molex plug on the foot pedal to the 4-pin socket in the back right side of the terminator control assembly. Note the locking action of the plug. See Figure 1-2. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 POWER SWITCH FUSE DRAWER FUSES VOLTAGE SELECTOR BLOCK Figure 1-2 220VAC Hookup The Hawk terminator will operate on 110VAC or 220VAC, 50 or 60 Hz. To change from one service to the other, do the following: (Refer to Figure 1-2 and 1-3) 1. Locate the power inlet module on the back of the control enclosure. 2. With a small screwdriver, remove the fuse drawer. 3. Remove the voltage selector block. 4. Rotate the voltage selector block until the correct voltage will show in the window. 5. Reinsert the voltage selector block. 6. 1 Amp fuses are recommended for either 110 or 220VAC so a fuse change is not required. 7. Replace the fuse drawer. 8. Install the proper power cord. NOTE: When servicing this machine, disconnect this power cord and the air to insure complete safety to service person. UNCONTROLLED COPY Page 9 of 48 Hawk Flat Cable Termination Machine Air Connection Because there are so many variations in air connections, Molex does not supply any type of fitting for air installation. Thus the user must supply a fitting of his choice to attach air of the correct pressure and volume to the 1/4 NPT port on the FR unit. Use 1/4in. line minimum. Once attached, adjust the regulator on the F-R to 80-85psig (See Section 1.7.1. Air will not flow into the machine proper until power is on and the “POWER ON” button is pressed. These terminators are easily changed from running FFC to running ribbon cable and visa-versa. To replace a worn punch or to change from one type of tooling to the other, do the following: 1. Remove the four (4) M4 screws holding the tooling cover. See Figure 1-4 and 1-5. 2. Remove the cover. 3. Remove the two (2) M5 flat head screws that hold the punches. TERMINATION PUNCH 62300-5002 New Molex Global Packaging Systems Tube verses Molex Current Tube In 2001 Molex changed from a 25 inch tube to our new Global Packaging Standard Tube which is 564 mm long (22.2 in.) These machines are easily adjusted to run either. See Section 2.1 for method. COVER 1.7 Changing Tooling Figure 1-5 CRIMP PUNCH 62300-5003 PUNCH 4. Remove the punch(s) that are there. There is a M5 tapped hole in the center of all the punches that a screw can be screwed into to push the punch out, if necessary. 5. Position the new punch(s) on the dowel pins. 6. Replace the holding screws and tighten. 7. Replace the cover. COVER Figure 1-4 Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 10 of 48 Hawk Flat Cable Termination Machine Section 2 Set-Up and Operation 2.1 Setup 2.2 Setting Batch Size 2.3 Setting Break off Strokes 2.4 Operation Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 UNCONTROLLED COPY Page 11 of 48 Hawk Flat Cable Termination Machine Note: 2 circuit connectors are loaded in pairs thus stop is set for 4 circuits 2.1 Setting Up Air Pressure Set the air pressure regulator on the F-R (filterregulator) to 5 - 6 BAR (80 - 90 psi). This is done by pulling out the adjustment knob and setting to the proper pressure, then pushing in the knob. Shuttle Adjustment (See Figure 2-1 and 2-2) SHUTTLE CYLINDER ADJUSTING KNOB LOCKING SCREWS Figure 2-1 Connector Feed Stop This stop is also adjustable from 3 to 25 circuits. To adjust the stop do the following: 1. Remove the nest guard. 2. Loosen the M5 locking screw on the connector feed stop located in front of the shift nest. 3. Starting from “3” circuits to the right, stop locates on every circuit position to 25 circuits. Adjust so that only 1 connector (except a pair of 2 circuits) at a time can enter the shift nest from the cartridge feed. Back edge of connector 1 must be just inside right edge of nest (.002 to .010in./.05 to .25mm). See Figure 2-3. CONNECTOR 1 CONNECTOR 2 The shuttle is adjustable from 3 to 25 circuits. To adjust the stop following the steps below: TERMINAL SUPPORT VIEW A M5 LOCKING SCREW CONNECTOR Figure 2-2 1. Place a connector in the termination nest all the way to the left. See Figure 2-2. 2. Bring the terminal support up. See Manual Operations in Section 2. 3. Extend the shuttle cylinder full out. 4. Loosen the two (2) locking screws under the shuttle cylinder. 5. Turn the adjusting knob clockwise to move the cylinder to the right (looking from the front) and counterclockwise to move it to the left. 6. Move the cylinder until the end of the shuttle rod just touches the connector. 7. Tighten the locking screws. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 CONNECTOR STOP Figure 2-3 4. When adjustment is set, tighten lock screw. 5. Replace guard. .002-.010 in. .05-.25mm CONNECTOR 2 CONNECTOR 1 Figure 2-3 VIEW A UNCONTROLLED COPY Page 12 of 48 Hawk Flat Cable Termination Machine 5. Repeat steps 2 and 3 until the termination depth is correct. 6. Tighten the lockout. 7. Replace the cover. Termination Depth Adjustment (See Figure 2-4) Termination depth is set as follows: WARNING: Make sure power is disconnected before doing steps 1 through 3. Changing From Molex 25 inch Tubes To New Global Packaging Systems (564 mm)Tubes and Back (See Figure 2-5) M10 SHCS AND JAM NUT 1. Remove the two (2) M4 screws in the right end of the tube feeder that hold the nozzle and support assembly assembly. See Figure 2-6. NOZZLE AND SUPPORT ASSEMBLY Figure 2-4 (With Cover off) Figure 2-6 1. Remove the control assembly cover. 2. Loosen the jam nut located on top of the termination head. 3. To raise the punch depth, turn the M10 screw clockwise. To lower, turn the M10 screw counterclockwise. The punch depth should be adjusted so that a terminated wire touches the lower surface of the terminal but is not crushed and the crimp tongs are securely gripping the wire without cutting into the insulation. See termination specifications on product drawings. SHUTTLE CYLINDER 2. Set aside the nozzle and support assembly. 3. If GPS tubes will be used, remove the two (2) M5 screws that hold the extension. See Figure 2-7. INSTALL EXTENSION FOR MOLEX TUBES REMOVE EXTENSTION FOR NEW GLOBAL PACKAGING SYSTEM TUBES NOZZLE AND SUPPORT ASSEMBLY SHIFT CYLINDER FEEDER EXTENSION Figure 2-5 SHIFT NEST 4. Terminate a wire and check the setting. Doc. No. TM-623002900 Revision: C M4 SHCS EXTENSION Release Date: 02-21-00 Revision Date: 08-01-12 AIR NOZZLE Figure 2-7 M5 SHCS 4. Store the extension and the two screws for future use. 5. If Molex standard tubes are to be used, install the extension using the (2) M5 SHCS. 6. Reinstall the nozzle and support assembly to the new end. See Figure 2-8B. UNCONTROLLED COPY Page 13 of 48 Hawk Flat Cable Termination Machine INSTALLED ON THE SHUTTLE MOUNT WITHOUT EXTENSION The same procedure is used if the operator wants to increase or decrease the number of breakoff strokes. 1. Press the blue "BK OFF" button on the operator interface. The following display will appear: BRKOFF STROKES = 0000 PRESS UP OR DOWN Figure 2-8A NOZZLE AND SUPPORT ASSEMBLY EXTENSION NOZZLE AND SHUTTLE ASSEMBLY 2. Use the up and down arrows to set the desired value in the display (0 - 9). 3. Press the "MAN" or the "RUN" button to exit Batch mode. 2.4 Operation M5 SHCS Figure 2-8B 2.2Setting Batch Size 1. Press the blue "BATCH" button on the operator interface. The following display will appear: This machine operates in two (2) modes; Manual and Run. Manual mode is used during setup and trouble shooting. It allows most machine functions to be operated independently, allowing adjustment, testing and repair of that function. here are built in interlocks to prevent collisions of machine parts and possible damage to same. Run mode sets the control to run a complete termination cycle when the foot pedal is pressed. This includes terminating the cable and connector, inserting terminals, and loading another connector automatically. BATCH COUNT = 0000 PRESS UP OR DOWN 2. Use the up and down arrows to set the desired value in the display. NOTE: Holding the arrow button down causes the incrementing to go faster. 3. Press the "MAN" or the "RUN" button to exit Batch mode. 2.3Setting Breakoff Strokes If the carrier breakoff option is not installed, it is necessary to enter a "0" in the breakoff stroke counter. If the carrier breakoff option is installed there must be a positive value (from 1 to 9) entered into the counter. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 Figure 2-9 MANUAL BUTTONS Manual Mode (See Figure 2-9) UNCONTROLLED COPY Page 14 of 48 Hawk Flat Cable Termination Machine 1. “MAN” (yellow) Pressing this button puts the controller into “Manual Mode”, and the display will show: MANUAL MODE PRESS MANUAL BUTTON 2. “CONN. LOAD (SEQ)” This button, when pressed, starts the sequence that loads another connector into the shuttle nest, then shuttles it forward, where the shuttle pushes the connector out of the slide nest into the termination nest. (Interlock: The terminal support must be down.) 3. “CONN. SHUTL” (See Figure 2-5 and 2-10) This button operates the shuttle cylinder. Pressing it once extends the cylinder rod forward pushing the connectors into the termination nest. Pressing it the second time, retracts the cylinder rod to the rest position. (Interlocks: Terminal support must be down and insert cylinder must be retracted. 4. "BREAK OFF" If the carrier breakoff option is installed, pressing this button causes the carrier breakoff mechanism to go up and down. (No Interlocks.) 5. “AIR FEED” Pressing this button once turns on the air that blows the parts out of the tube into the shift nest. Pressing it a second time turns off the air. CONNECTOR IN SHIFT NEST 7. “TERM-INATE” Pressing this button extends the termination cylinder which in turn brings down the termination die. Pressing it a second time retracts the cylinder, raising the termination die. (Interlock: Insert must be retracted.) 8. “INSERT IN/OUT” Pressing this button extends the insertion cylinder which pushes connector housing onto the terminals and cable. Pressing it a second time returns the guide to the rest position. (Interlocks: Termination die must be up and terminal support must be down.) 9. “TERM. SUPRT” (See Figure 2-2) In the termination nest there is a series of blades mounted on a block that locate and support the terminals when a connector is in the nest. This button raises and lowers the support. (No Interlocks.) 10. “ALARM CLEAR” (Red Button) As noted with each button above, there are interlocks to prevent damage to various parts of the machine. If one of these interlocks is violated, a warning message comes up on the display indicating which interlock is violated the action does not occur and the alarm goes off. The alarm cause must be corrected. Then the operator must press the “ALARM CLEAR” button to clear this message before proceeding. See Section 3.4 for more information. SHUTTLE CYLINDER NOTE: By pressing E-STOP, the air can be dumped for clearing jams. Run Mode SHIFT NEST SHIFT CYLINDER Figure 2-10 6. “CONN. SHIFT” (See Figure 2-10) Pressing this button causes the connector in the shift nest to move to the rear position. Pressing it a second time returns the nest to the forward or rest position. (Interlock: Shuttle must be retracted.) Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 1. The first connector must be manually loaded into the termination nest. Press the "MAN" button. 2. Press the "CONN. LOAD" button. This will put the terminator through all operations necessary to load the connector. 3. Press the "RUN" button. The operator is now ready to begin a run. The following display will appear. RUN MODE BATCH XXXX PRESS FOOT SWITCH UNCONTROLLED COPY Page 15 of 48 Hawk Flat Cable Termination Machine 4. Place a length of flat cable against the cable guide and slide it forward until the leading edge of the cable touches the connector housing. See Figure 2-11. 8. Repeat steps 4 through 7 as often as required to reach the desired batch size. When the batch is completed, the following display will appear and the bottom line will flash: BATCH COMPLETED 0000 PRESS ALARM CLEAR CONNECTOR CONNECTOR CABLE GUIDE 9. Press the "ALARM CLEAR" button. 10. The operator can now go to Manual mode and set up for a new job or he can press the "RESET" button (which will reset the batch count to "0") and run another batch. BEND CONNECTOR FLAT CABLE Figure 2-11 5. Press and release the foot pedal. 6. When the terminator has completed its cycle, the terminated cable and connector will be pushed out the left side of the termination nest and a new connector is loaded. 7. Break off the carrier strips by inserting them in the slot in the front of the cable support (See Figure 2-12) and bending back and forth once or twice. NOTE: If the optional carrier breakoff assembly is installed the above step is not necessary. Doc. No. TM-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-01-12 FFC OR RIBBON CABLE Figure 2-12 UNCONTROLLED COPY Page 16 of 48 Hawk Flat Cable Termination Machine Section 3 3.1. Maintenance 3.2. Perishable Parts 3.3. Spare Parts 3.4. Troubleshooting 3.5. Fault Message Diagnostics Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 17 of 48 Hawk Flat Cable Termination Machine 3.1 Maintenance WARNING: Disconnect the compressed air line and the power cord from the power source during all maintenance operations. Cleaning 1. Using a small soft brush, clean all the debris and dust out of both nests and the tooling at least once a day, NOTE: The use of compressed air to clean the tooling is not recommended as it can cause debris to wedge into the tooling and/or come flying out at the operator. 2. When it is necessary to replace tooling, care should be taken to remove any debris from tapped holes or mounting surfaces. Debris can prevent tooling from being properly locked into position. 3. Keep the air filter clean. A visible coating of dirt in the bowl indicates that the unit needs cleaning. To clean, Remove the bowl and filter element and clean with denatured alcohol. Lubrication Sparingly lubricate the sliding parts approximately every month with S.A.E. 10W motor oil or equivalent. Preventive Maintenance Chart Daily: Clean. See Section 3.1. Monthly: Cleck air fliters and clean as necessary. See Section 3.1. Lubricate sliding parts. See Section 3.2. CHECK SHEET MONTH Week Daily Use YEAR _________ Days of the Week MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Monthly Air Filters Lubricate Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the tool. Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 18 of 48 Hawk Flat Cable Termination Machine 3.2 Perishable Parts These parts make contact with the connector and can wear over time. The customer is responsible for maintaining a set of these parts and Molex recommends the customer keep at least one spare set on hand at all times. NOTE: Perishable Parts are identified in the Parts Lists in Section 6. 3.3 Spare Parts These are parts that are available to support the Hawk terminators in service. They are moving or otherwise functioning parts that could be damaged or malfunction. It is suggested that the customer may want to keep some or all of these parts on hand to reduce down time. NOTE: Recommended Spare Parts are identified in the Parts List in Section 6. 3.4 Troubleshooting Symptom No Power Cause No power at source Loose connection or damaged power cord. Terminator fuses blown. Connector over feeding or short feeding in termination nest. Shuttle feed improperly set. Solution Make sure there is power at the power outlet. Check both ends of the power cord to be sure they are firmly plugged in. Check the power cord and repair or replace as required See Section 1.6 for locating and removing fuses. Check and replace as required. See Section 2.2 and check the shuttle feed. Reset if required. See Section 2.2 and check the cable guide Position and reset if necessary. Termination punch height set too See Section 2.1 and readjust the termination high or too low. Depth. Air pressure too low. Check and correct. See Section 2.1. Cable guide not set correctly. Cable not terminating correctly in connector. Machine stops and a fault message appears in the display. Doc. No. ATS-623002900 Revision: C A machine function has failed to perform as expected. Release Date: 02-21-00 Revision Date: 08-28-12 See "Fault Message Procedure" on following page. UNCONTROLLED COPY Page 19 of 48 Hawk Flat Cable Termination Machine 3.5 Fault Message Procedure This terminator has built in fault diagnostics. When an action fails to occur properly, a fault message will appear in the display. This messages indicates what did not happen and what sensor the controller is expecting to see. For Example: The following display appears: S5 HSG. SHUTTLE NOT FORWARD This message tells us the following: The controller is looking to see sensor S5 on and either the shuttle did not move at all, it moved and jammed part way, or it went all the way but the sensor is not made. The following example, while it uses the above message to explain the procedure, it is typical of the method for handling most fault messages. 1. Determine where the shuttle rod is: Is it all the way home, part way forward, or all the way forward (to the Left)? 2. If the shuttle rod is all the way forward jump to step 6. 3. If the rod did not move, check to see if the valve (SV5 in this case), is functioning correctly. See Pneumatic Diagram in Section 5. Replace if necessary. 4. If the rod did not move or moved part way, check for bent cylinder rod, loose mechanical joints or debris in the path of the rod. Also check the air pressure. 5. Repair, replace, clean or adjust as required. 6. Locate the appropriate sensor and determine if it is functioning properly by placing a piece of steel in front of sensor. If the LED on the back of the sensor goes on, the sensor is OK. If LED does not go on, check the plug. If this is OK, replace the sensor. 7. Make sure the sensor flag (if there is one) is positioned so that it activates the sensor when the shuttle is all the way forward. 8. From the electrical schematic (See Section 6) it is determined that Sensor 5 is wired to input 008. Find input 008 LED on the controller in the control cabinet. Check to see if this LED goes on when the sensor LED goes on. If not, check the wiring between the sensor and the controller. Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 20 of 48 Hawk Flat Cable Termination Machine Section 4 Optional Carrier Breakoff Station Order No. 62300-4700 4.1 Description 4.2 Technical Specifications 4.3 Installation 4.4 Operation Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 21 of 48 Hawk Flat Cable Termination Machine 4.3 Installation and Removal 4.1 Description (See Figure 4-1) The optional 62300-4700 Carrier Breakoff Station is designed to mount on the left side of the basic terminator. It automatically breaks the carrier strip off the finished connector and cable assembly. The carrier strip then slides down the chute into a customer provided container. BRAKOFF CAM CONNECTOR TRACK Installation To install the optional Carrier Breakoff Assembly, do the following steps. 1. Remove the gib from the left side of the termination nest as shown in Figure 4-2. 2. Install the breakoff assembly (without the strip chute) into the area where the gib was removed. The rear bolt hole and the two dowels will line up with the holes in the mating block. See Figure 4.3. CARRIER BREAK OFF ASSEMBLY BRAKOFF CYLINDER CARRIER STRIP CHUTE Figure 4-1 4.2 Technical Specifications Width: 78.8 mm (3.1 in.) Depth:65.1 mm (2.56 in.) Height:70.5 mm (2.78 in.) Weight: 0.9 kg (2 lbs.) M6 SHCS Figure 4-3 M4 SHCS 3. Install the two (2) M6 screws that hold the breakoff assembly down. 4. Remove the two (2) plugs from the A and B ports of the spare valve in the valve bank. 5. Connect two lengths of 4mm tubing from the valve assembly to the cylinder. Connect the “B” port to the top fitting on the cylinder and the “A” port to the bottom fitting. Reference the Pneumatic Schematic in Section 6. 6. Looking at Figure 4-4, locate the carrier strip chute and mount with two (2) M4 screws. Removal If for some reason you want to un-install the carrier breakoff assembly, simply reverse the installation procedure described above. REMOVE GIB Figure 4-2 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 CAUTION: It is important to make sure the gib, removed in step 1 above, is reinstalled. UNCONTROLLED COPY Page 22 of 48 Hawk Flat Cable Termination Machine M4 SCREWS Figure 4-4 INSTALL PLUGS 62500-0127 CHUTE Figure 4-5 (With Cover removed) Tubing Hookup 4.4 Operation No Breakoff If the breakoff station is removed do the following: 1. Remove the two (2) tubes (that went to the breakoff station) from the valve bank. 2. Install two (2) plugs in the right hand ports as shown in Figure 4-5 (where the tubes were just removed). Once the tubing is connected, the carrier breakoff assembly is ready to go. The control is preprogrammed to operate the breakoff cycle automatically. NOTE: A value greater than "0" must be programmed into the breakoff stroke counter for the breakoff to function. See Section 2.3 for programming procedure. With Breakoff If the breakoff station is being installed, do the following: 1. Remove the two (2) plugs from the spare valve (#8). 2. Install two 6mm to 4mm reducers in these ports. 3. Cut the piece of tubing supplied with the breakoff kit into two suitable lengths to run as shown in Figure 4-6. 4. Insert the tubes into the reducers. 5. Connect the other ends of the tubes to the breakoff cylinder as shown in Figure 4-6. Tube "A" connects from the "A" (bottom) port on the valve manifold to the top port of the breakoff cylinder, and the "B" tube connects from the "B" (upper) valve manifold port to the bottom port of the breakoff cylinder. See also the Pneumatic Schematic at the end of Section 6. Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 TUBE A TUBE B 62500-0138 REDUCERS TUBE B TUBE A Figure 4-6 (With Cover removed) UNCONTROLLED COPY Page 23 of 48 Hawk Flat Cable Termination Machine Section 5 5.1. Parts Lists and Assembly Drawings 5.2. Electrical Controls and Schematics 5.3. Pneumatic Schematics Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 24 of 48 Hawk Flat Cable Termination Machine The following pages contain the parts lists and assembly drawings for the 62300-2900 and 62300-3000 Hawk Terminators. Here is some information that will help you better understand and use the information contained in these documents. 1. The "Item No" in the left column of the parts lists matches the number in the bubble on the assembly drawings. 2. The "Order No." in the next column is the number that should be used when ordering that particular part. 3. An "RSP" appearing at the end of the Description column designates this part as a Molex Recommended Spare Part. 4. A "PP" appearing at the end of the Description column designates this part as a Perishable Part. 5. The "Req'd" quantity is the number of pieces of that part required per assembly. It is also the quantity Molex recommends be kept on hand if that part is a Perishable Part or a Recommended Spare Part. Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 25 of 48 Hawk Flat Cable Termination Machine 5.1 62300-2900 Parts List and Assembly Drawings Item 1 2 3 4 5 6 7 8 9 Order No. 11-31-5302 11-41-0265 62300-2600 62300-2700 62300-3400 62300-3500 62300-5100 62800-7317 63800-8394 62300-2900 – FFC/SL Hawk Assembly Figure 5-1 Engineering No. Description AM60510-122 Tool, Nest Cleaning KM242 Logo, 6” Molex 62300-2600 Assembly, Tube Feeder 62300-2700 Assembly, Hawk Controls 62300-3400 Assembly, Press 62300-3500 Assembly, SL Insert and Termination Nest 62300-5100 Tooling, FFC/SL Termination 62800-7317 Tag, "CE" Serial Number 63800-8394 Foot Switch Qty 1 1 1 1 1 1 1 1 1 2 4 5 7 8 6 3 1 9 Figure 5-1 62300-2900 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 26 of 48 Hawk Flat Cable Termination Machine 62300-2950 Parts List and Assembly Drawings Item 1 2 3 4 62300-2950 – Ribbon Cable SL Hawk Assembly Figure 5-2 Order No. Engineering No. Description 62300-2600 62300-2600 Tube Feeder Assembly 62300-3400 62300-3400 Press Assembly, 99 Hawk 62300-3500 62300-3500 SL Insert and Termination Nest Assembly 62300-5100 62300-5100 FFC/SL Termination Tooling Qty 1 1 1 1 2 4 3 1 Figure 5-2 62300-2950 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 27 of 48 Hawk Flat Cable Termination Machine 62300-3000 Parts List and Assembly Drawings Item 1 2 3 4 5 6 7 8 9 62300-3000 – Ribbon Cable SL Hawk Assembly Figure 5-3 Order No. Engineering No. Description 11-31-5302 11-31-5302 Tool, Nest Cleaning 11-41-0265 KM242 Logo, 6” Molex 62300-2600 62300-2600 Assembly, Tube Feeder 62300-2700 62300-2700 Assembly, Hawk Controls 62300-3400 62300-3400 Assembly, Press 62300-3500 62300-3500 Assembly, SL Insert and Termination Nest 62300-5000 62300-5000 Tooling, FFC/SL Termination 62800-7317 62800-7317 Tag, "CE" Serial Number 63800-8394 63800-8394 Foot Switch Qty 1 1 1 1 1 1 1 1 1 2 4 5 7 8 6 3 1 9 Figure 5-3 62300-3000 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 28 of 48 Hawk Flat Cable Termination Machine 62300-5200 and 62300-5300 Parts List and Assembly Drawings 62300-5200 – A 62300-2900 with Carrier Break off Figure 5-4 Item No. Order No. Description Qty 1 62300-2900 Assembly, FFC/SL Hawk 1 2 62300-4700 Assembly, Carrier Break off 1 62300-5300 – A 62300-3000 with Carrier Break off Figure 5-4 Item No. Order No. Description Qty 1 62300-3000 Assembly, FFC/SL Hawk 1 2 62300-4700 Assembly, Carrier Break off 1 1 2 Figure 5-4 62300-5200 and 62300-5300 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 29 of 48 Hawk Flat Cable Termination Machine 62300-2600 Parts List and Assembly Drawings Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Doc. No. ATS-623002900 Revision: C 62300-2600 – Tube Loader Assembly Figure 5-5 Order No. Engineering No. Description 11-32-5624 63163Z316 Switch, Shuttle Cylinder Proximity 62300-2601 62300-2601 Base, Shuttle 62300-2602 62300-2602 Mount, Shuttle 62300-2603 62300-2603 Bracket, Tube Rest 62300-2604 62300-2604 Rest, Tube 62300-2606 62300-2606 Base, Shift 62300-2607 62300-2607 Spacer, Left 62300-2608 62300-2608 Spacer, Right 62300-2609 62300-2609 Nest, Shift 62300-2610 62300-2610 Guide, Left Shift 62300-2611 62300-2611 Guide, Right Shift 62300-2612 62300-2612 Cover, Shift Nest 62300-2613 62300-2613 Stop, Tube Stop 62300-2614 62300-2614 Bracket, Shift Nest 62300-2615 62300-2615 Nozzle, Tube Feed Air 62300-2616 62300-2616 Block, Cylinder Adjusting 62300-2617 62300-2617 Screw, Adjusting 62300-2618 62300-2618 Cover 62300-2619 62300-2619 Holder, Tube 62300-2620 62300-2620 Mount, Cylinder 62300-2621 62300-2621 Preload, Tube 62300-2628 62300-2628 Guide, Terminal Feed 62300-2630 62300-2630 Stop, Shift 62300-2631 62300-2631 Extension, Shuttle Mount 62300-2634 62300-2634 Guard, Shift 62300-3702 62300-3702 Pusher, Shuttle 63600-0055 63600-0055 Bracket, Prox Mount 63600-0283 63600-0283 Washer, Thrust 63600-0350 63600-0350 Plunger, Ball 63600-0575 63600-0575 Collar, Set Screw 63600-0709 63600-0709 Cylinder, Shift RSP 63600-0710 63600-0710 Cylinder, Shuttle RSP 63600-0770 63600-0770 Bearing 63600-0789 63600-0789 Knob 63600-0826 63600-0826 Bracket, Cylinder 63600-1179 63600-1179 Thumb Knob with M5 by 10 Long SHCS 63600-1583 63600-1583 Thumb Knob with M4 by 10 Long SHCS RSP - Part is a Molex Recommended Spare Part. Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Qty 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 2 2 1 Page 30 of 48 Hawk Flat Cable Termination Machine 62300-2600 Assembly Drawing 27 1 25 32 36 (2) 17 (2) 35 11 (2) (2) 15 26 30 34 12 (2) 18 20 22 5 16 19 2 23 4 10 9 24 3 (2) 28 14 33 6 21 8 7 31 Doc. No. ATS-623002900 Revision: C Figure 5-5 62300-2600 29 13 Release Date: 02-21-00 Revision Date: 08-28-12 37 UNCONTROLLED COPY Page 31 of 48 Hawk Flat Cable Termination Machine 62300-3400 Parts List and Assembly Drawings 62300-3400 – Hawk Press Assembly Figure 5-6 Order No. Engineering No. Description Qty 62300-3401 62300-3401 Base, Nest 1 62300-3402 62300-3402 Upright, Left Frame 1 62300-3403 62300-3403 Upright, Right Frame 1 62300-3404 62300-3404 Pin, Pivot 1 62300-3405 62300-3405 Support, Nest 1 62300-3406 62300-3406 Plate, Press Top 1 62300-3407 62300-3407 Mount, Termination Cylinder Pivot 1 62300-3408 62300-3408 Guard, Punch 1 62300-3409 62300-3409 Lever, Press 1 62300-3410 62300-3410 Base, Machine 1 62300-3411 62300-3411 Pivot, Cylinder 1 62300-3412 62300-3412 Guide, Left Termination 1 62300-3413 62300-3413 Guide, Right Termination 1 62300-3414 62300-3414 Slide, Termination 1 62300-3415 62300-3415 Slide, Upper Termination 1 62300-3416 62300-3416 Fulcrum, Lever 1 62300-3417 62300-3417 Bracket, Sensor 1 63600-0725 63600-0725 Cylinder RSP 1 63600-0726 63600-0726 Clevis 1 63600-0727 63600-0727 Mount, Swivel 1 63600-0785 63600-0785 Foot, Leveling 4 N/A N/A M10 by 40 long SHCS 1** N/A N/A M10 Hex Nut 1** RSP - Part is a Molex Recommended Spare Part. ** Available from an industrial supply company such as MSC (1-800-645-7270). Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 32 of 48 Hawk Flat Cable Termination Machine 62300-3400 Assembly Drawing 22 23 6 17 8 13 2 9 16 19 15 18 4 14 12 1 10 11 20 5 7 3 Figure 5-6 62300-3400 21 (4) Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 33 of 48 Hawk Flat Cable Termination Machine 62300-3500 Parts List and Assembly Drawings 62300-3500 – SL Insert and Termination Nest Figure 5-7 Order No. Engineering No. Description Qty 11-32-3059 63222E18 Sensor, Proximity RSP 1 11-40-5203 63303T112 Spring, Compression RSP 4 62300-3501 62300-3501 Support, Terminal 1 62300-3502 62300-3502 Anvil PP 1 62300-3504 62300-3504 Bar, Insertion 1 62300-3505 62300-3505 Base, Nest 1 62300-3506 62300-3506 Cover, Nest 1 62300-3507 62300-3507 End, Rod 1 62300-3508 62300-3508 Slide, Nest 1 62300-3509 62300-3509 Base, Slide 1 62300-3510 62300-3510 Gib, Slide 2 62300-3511 62300-3511 Mount, Table 1 62300-3512 62300-3512 Table, Feed 1 62300-3513 62300-3513 Spring, Drag RSP 1 62300-3514 62300-3514 Base, Tooling 1 62300-3516 62300-3516 Bar, Locating 1 62300-3517 62300-3517 Bar, Break off 1 62300-3518 62300-3518 Bar, Inner Break off 1 62300-3519 62300-3519 Guide, Cable 1 62300-3520 62300-3520 Clamp, Cable Guide 1 63600-0724 63600-0724 Cylinder RSP 1 63600-0730 63600-0730 Cylinder RSP 1 63600-0761 63600-0761 Screw, Shoulder 1 N/A N/A M8 by 30 long SHCS 1** N/A N/A M8 Hex Nut 1** PP- Part ia a Molex Recommended Perishable Part. RSP - Part is a Molex Recommended Spare Part. ** Available from an industrial supply company such as MSC (1-800-645-7270). Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 34 of 48 Hawk Flat Cable Termination Machine 62300-3500 Assembly Drawing 21 14 13 7 23 (4) 2 3 19 6 8 18 10 5 11 17 (2) 22 9 15 4 20 1 16 12 24 Figure 5-7 62300-3 500 25 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 35 of 48 Hawk Flat Cable Termination Machine 62300-4700 Parts List and Assembly Drawings Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 62300-4700 – Optional Carrier Break off Station Figure 5-8 Order No. Engineering No. Description 11-31-6809 AM60018-46 Fitting, M5 Thad. to 4mm Tube (Not Shown) 62300-4701 62300-4701 Nest 62300-4702 62300-4702 Cover, Nest 62300-4703 62300-4703 Block, Slide 62300-4704 62300-4704 Bar, Break off 62300-4705 62300-4705 Mount, Break off Bar 62300-4706 62300-4706 Deflector, Carrier 62300-4707 62300-4707 Base 62300-4708 62300-4708 Plate, Mount 62300-4709 62300-4709 Standoff 62300-4710 62300-4710 Pin 62300-4711 62300-4711 Chute 62500-0138 62500-0138 Reducer (Not Shown) 63600-0723 63600-0723 Cylinder RSP 63600-0915 63600-0915 Bearing 63600-0918 63600-0918 Screw, Shoulder Tubing, 4mm (Not Shown) RSP - Part is a Molex Recommended Spare Part. Qty 2 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1m 62300-4700 Assembly Drawing 3 Figure 5-8 62300-4700 2 16 (2) 5 15 9 4 10 (2) 11 6 8 7 14 12 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 36 of 48 Hawk Flat Cable Termination Machine 62300-5000 and 62300-5100 Parts List and Assembly Drawings 62300-5000 – Ribbon Cable SL Tooling Figure 5-9 Item No. Order No. Description 1 62300-5002 Punch, Termination PP 2 62300-5003 Punch, Crimp PP PP- Part ia a Molex Recommended Perishable Part. Qty 1 1 1 Figure 5-9 62300-5000 2 62300-5100 – FFC/SL Tooling Figure 5-10 Item No. Order No. Description Qty 1 62300-3503 Punch PP 1 PP- Part ia a Molex Recommended Perishable Part. 1 Figure 5-10 62300-5100 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 37 of 48 Hawk Flat Cable Termination Machine 5.2. Electric Controls Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Order No. 11-32-1659 11-32-1660 11-32-2733 11-32-3059 11-32-5182 11-32-5376 11-32-6551 11-32-6552 62300-2701 62300-2703 62300-2705 62300-2706 62300-2707 62300-2708 62300-2709 62300-2722 62300-2723 62300-2724 62300-2725 62500-0050 62500-0051 62500-0078 62500-0122 62500-0123 62500-0126 62500-0161 62500-0189 62500-0460 62500-0478 62500-0490 62500-0515 62500-0534 62500-0608 62500-0609 62500-0610 62500-0611 62500-0612 62500-0613 62500-0614 62500-0615 62500-0689 62500-1055 69018-6221 69018-6228 69018-6231 Doc. No. ATS-623002900 Revision: C 62300-2700 Electric Controls Engineering No. Description 11-32-1659 Cord, 3-Cond. Detachable (NOT SHOWN) 11-32-1660 Fuse, 1A. Slow Blow 11-32-2733 Drawer, 2-Pole Fuse 11-32-3059 Switch, 8mm Proximity (See Mechanical Assemblies) 11-32-5182 Receptacle, Casing 11-32-5376 Elbow 11-32-6551 Relay, 3 Pole 11-32-6552 Socket, 3 Pole Relay 62300-2701 Enclosure 62300-2703 Cover, Front 62300-2705 Mount, Rear 62300-2706 Mount, Rear Control 62300-2707 Mount, Front Control 62300-2708 Panel, Control 62300-2709 Mount, Valve 62300-2722 Panel, Operator 62300-2723 Mount, Lower Panel 62300-2724 Mount, Rear Panel 62300-2725 Mount, Right Panel 62500-0050 Terminal, Side Entry 62500-0051 Clamp, End 62500-0078 Plug, 8mm Tube 62500-0122 Manifold, 8-Station 62500-0123 Valve, Single Solenoid RSP 62500-0126 Muffler 62500-0161 Plate, Terminal End 62500-0189 Filter/Regulator 62500-0460 Module, Peripheral Port to RS232 62500-0478 Cable, 8mm Proxy. Right Angle (NOT SHOWN) 62500-0490 Valve, Slow Start 62500-0515 CPU 62500-0534 Supply, Power 62500-0608 Display 62500-0609 Block, Lighted N.O. Contact 62500-0610 Operator, Lighted Push Button 62500-0611 Plate, 'E-Stop' Legend 62500-0612 Plate, 'Power On' Legend 62500-0613 LED, Green 62500-0614 Switch, Red Mushroom Head 62500-0615 Block, N.C. Contact 62500-0689 Cable, CPU to Operator Interface 62500-1055 Receptacle, Footswitch 69018-6221 Insert, Voltage Selector 69018-6228 Counter, 7 Digit Non-Reset able 69018-6231 Diode RSP - Part is a Molex Recommended Spare Part. Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Qty 1 4 1 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 4 1 1 8 2 2 1 1 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Page 38 of 48 Hawk Flat Cable Termination Machine 9 Electric Controls (Cont.) 33 34 35 37 36 38 39 40 16 10 62300-2700 (1 of 3) 6 62300-2700 (2 of 3) 27 42 11 3 Doc. No. ATS-623002900 Revision: C 5 43 BACK VIEW Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 39 of 48 Hawk Flat Cable Termination Machine Electric Controls (Cont.) 14 19 18 10 31 8 41 28 (2) 7 45 32 44 26 17 (2) 13 24 (8) 25 21 (4) 23 (2) 20 11 (Ref) (15) Doc. No. ATS-623002900 Revision: C 30 15 Release Date: 02-21-00 Revision Date: 08-28-12 22 UNCONTROLLED COPY 62300-2700 (3 of 3) Page 40 of 48 Hawk Flat Cable Termination Machine Electric Schematics 62300-2721 Sheet 1 of 3 62300-2721 Sheet 3 of 3 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 41 of 48 Hawk Flat Cable Termination Machine Electric Schematics (Cont.) 62300-2721 Sheet 2 of 3 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 42 of 48 Hawk Flat Cable Termination Machine 5.3 Pneumatic Diagram PNEUMATIC DIAGRAM 62300-2721 Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 43 of 48 Hawk Flat Cable Termination Machine Section 6 Glossary of Terms Carrier Circuit Size Strip that temporarily holds the terminals in position during shipping and termination. Must be removed upon completion of assembly. Number of conductors in a connector. Crimp To form tabs on a terminal around a wire conductor or insulator. Connector An assembly of a housing and a series of terminals. Discrete Wire Individual wires terminated to a connector. FFC The abbreviation for "Flat Flex Cable", a type of ribbon cable where the conductors are conductive film strips between two layers of insulation making the cable very thin. Housing Plastic connector body. Insertion Pushing terminals into the housing. Insulation Displacement A wire termination technique where the terminal pierces the wire insulation, and makes contact with the conductor without the need for stripping the wire. Punch The tooling piece that crimps (or terminates) wires to terminals. Sensor Electrical non-contact switch that detects the presence of metal moving into its field and signals the machine control. SL Molex trade mark for its modular, single row wire-to-board and wire-to-wire system. Terminal The parts (2 or more) of the connector assembly to which the wire is attached and provides the internal conductor. Termination The process of attaching the wire to the terminal. Termination Head The part of the machine that holds the crimp and termination punches and terminates the wires into the terminals. Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 44 of 48 Hawk Flat Cable Termination Machine Section 7 Statistical Process Control (Summary) 7.1 I.D.T. Termination Process Control 7.2 Process Capability 7.3 Production Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 45 of 48 Hawk Flat Cable Termination Machine 7.1 I.D.T. Termination Process Control The I.D.T termination process is the interaction of a terminal, wire, tooling, personnel, methods and procedures, and environmental attributes that, when controlled, produce a quality termination. Quality control is an important aspect to quality termination. It should not take excessive setup or inspection time to implement, and can save a harness manufacturer thousands of dollars in potential rework or re-manufacturing. The key to quality is to target nominal specifications while continuously reducing variability. Variability is the slight changes that occur from wire to wire. There are two types of variability, common and special. Common sources of variation are those causes that affect the process uniformly, and are created from numerous small sources. Common variability are inherent tolerances within a reel of wire, terminals or connector housings. Also, common variability is created by the natural tolerances of the harness assembly machines. Reduction of variability at the common level normally has to come from changes at the wire, terminal, and tooling manufacturer. The second source of variability is referred to as special cause. Unlike common cause, special sources of variation occur irregularly and unpredictably. Without checks throughout a run, a tool becoming loose after the first hundred cycles, or a damaged tool from a jam, may be undetected until thousands of assemblies are made. This section assumes that the termination depth is being measured with a resolution of .025 mm (.001 in), and pull force is measured with a resolution of 1 N (.25lbs). 7.2 Process Capability Molex qualifies each I.D.T terminator for termination depth and vertical pull force. (where applicable) This qualification is performed on a specified sample, and is targeted at 2 CpK. Before a new tool is put in production, it is Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 recommended that a capability study be done by the customer using their specific wire in their process. A capability study is based on the assumption of a normal distribution (bell-type curve). It provides an estimate on the probability of a measurement being outside of specification. CpK 0.67 1 1.33 1.67 2 +/- Sigma 2 3 4 5 6 % Yield 95.45 99.73 99.99 99.99+ 99.99++ PPM 45,500 2,699 63 0.57 0 PPM - Parts per million potential defects. A minimum of a 25 piece sample should be run. The average and standard deviation should be calculated for each specification. A capability index defined by the formula below. Cp may range in value from 0 to infinity, with a larger value indicating a more capable process. A value >1.33 is normally considered acceptable. Tolerance 6*Standard Deviation The CpK index indicates whether the process will produce units within the tolerance limits. CpK has a value equal to Cp if the process is centered on the mean of specification; if CpK is negative, the process mean is outside the specification limits; if CpK is between 0 and 1 then some of the 6 sigma spread falls outside the tolerance limits. If CpK is larger than 1, the 6 sigma spread is completely within the tolerance limits. CpK is calculated with the lesser of the following formulas: (USL - MEAN) 3*Std Deviation (LSL - MEAN) 3*Std Deviation USL = Upper Specification Limit, LSL = Lower Specification Limit Six sigma is a goal of many companies because it represents virtually zero defects. The ability of a company to achieve a six sigma level is dependent on the amount of common variability in their UNCONTROLLED COPY Page 46 of 48 Hawk Flat Cable Termination Machine process. A termination hand tool will produce more variability than a bench mounted terminator. Operator run terminators will produce more variability than a fully automatic machine. A portion of the variability in harness assembly will come from the instruments used to measure the parts and the ability of an operator to repeat the measurement. A drop gauge will measure more accurately than a dial caliper. An automatic pull force system will measure better than a hook type scale. It is important that the measurement gage has enough resolution. Also, two operators may measure the same part differently, or the same operator may measure the part different when using two types of gages. A gage capability study is recommended to identify what part of the variability is coming from measurement error. The variability from measurement error can keep CpK's low. The capability of the process should be reconfirmed if the production data is significantly different from the capability study. 7.3 Production Once the level of capability is established, the machine is ready for production. Many harness manufacturers run only a few hundred or few thousand wires at one time. In this case, it is not practical or economical to run a twenty-five piece capability with every setup. Setup Confirmation After the setup of the termination process, terminate five terminals with a shallow termination depth. Visually inspect for tooling marks on the terminal and housing, and measure termination depth. Make the appropriate adjustments to the machine. (Refer to product termination specification and problem checklist sections if needed.) After all adjustments have been made, terminate five more samples for termination depth neasurement. Then measure and document the average depth, the maximum reading, and the minimum reading. The range is considered the maximum reading minus the minimum reading. With a drop gauge and an experienced operator, the range for termination depth is normally only a Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 few thousandth of an inch. This data becomes the first point on the control chart. When the termination depth has been confirmed, the vertical pull force can be measured. This checks the capability of the insulation crimp (strain relief) to hold the wire to within the specification limits. This is best done with an automatic pull force system. Production (Control Charting) It should be normal procedure for the operator to visually check the terminal area for damage or improper termination. Termination should be checked throughout the run. The frequency of each check is determined by the risk you wish to take for scraping parts. A check every 250 to 500 parts is recommended. Control Charting Terminationdepth is normally control charted since it is a quick nondestructive measurement and is critical for the electrical reliability of the termination. There are three primary purposes for control charting. First, the number of setup samples are normally small, and its statistical value is limited. Second, since special-cause effects on a process are irregular and unpredictable, it is necessary to have a means of catching changes in the process as soon as they occur. This prevents thousands of terminations from being scrapped after the run is over. Third, and most important, this data is necessary to assess and improve the process. Once the tooling process is setup and the wire size is not changing, keep one control chart for wire color changes, wire length changes, or setup adjustments. Record the data point on the chart before an adjustment is made. If data is recorded after each adjustment, the process most likely will assume control and provide little data for improving the process. Write as many notes on the chart as possible. The only truly effective and economically sensible manner of managing a manufacturing process is to understand, monitor, and reduce sources of variability inherent to the process itself. Every minute the process is down for setup or adjustment is unproductive. UNCONTROLLED COPY Page 47 of 48 Hawk Flat Cable Termination Machine Example Control Chart Thousandths Crimp Height 31.5 Sample 30.5 Contol Limit Control Limit adjustment, but a close evaluation of the tooling. A shift in the process between operators would not indicate an adjustment, but an evaluation of measurement capability. The idea of the control chart is to identify what caused the shift to justify if an adjustment to the process is warranted. Upper Specification 29.5 Lower Specification 28.5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Measurements Refer to the Example Control Chart above. What does this sample chart tell us? A process shift occurred between measurement 12 and 13. This type of shift could occur due to a change in wire, a change in connector lots, a jam in the machine that damaged the tooling, a change in operators, or an adjustment to the machine. Since the measurements are still within specification, would you stop production to make adjustments? I.D.T.termination processes have been producing product within specification for many years. Today with statistical process control, the philosophy of quality is being within specification, is being replaced by being on target with continuous reduction in variability. Control charting is a tool that truly allows a company to understand their process. ATTENTION Reference must always be made to product application / termination specification to determine harness assembly parameters. A shift in the process due to a change in wire insulation may warrant a termination depth adjustment. A shift after a jam would not indicate an Visit our Web site at http://www.molex.com Doc. No. ATS-623002900 Revision: C Release Date: 02-21-00 Revision Date: 08-28-12 UNCONTROLLED COPY Page 48 of 48