RAST2.5 Semi-Automatic Terminator Machine
RAST2.5 SEMI-AUTOMATIC TERMINATOR MACHINE
For Appli-Mate™ Connectors
Instruction Manual
Order No. 62300-6200
Description
Operation
Maintenance
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
WARNING
NEVER
USE THIS FIXTURE WITHOUT THE GUARDING OR OTHER SAFETY DEVICES
IN PLACE, GUARD DOORS CLOSED AND GUARD OVERRIDE SWITCHED
“OFF”.
FIXTURE GUARDING IS DESIGNED TO PREVENT HANDS FROM REMAINING
IN THE DANGER AREAS OF THE FIXTURE.
RUNNING THIS FIXTURE WITHOUT GUARDS, UNDER ANY
CIRCUMSTANCES, CAN CAUSE SERIOUS INJURY.
NEVER
OPERATE, SERVICE OR ADJUST THIS FIXTURE WITOUT PROPER
INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE
INSTRUCTIONS IN THE OPERATING MANUAL.
NEVER
SERVICE THIS FIXTURE WHILE IT IS CONNECTED TO ANY ELECTRICAL
POWER SOURCE. DISCONNECT POWER BY SWITCHING OFF THE MAINS
ISOLATOR.
WORK SAFELY AT ALL TIMES
For Service, Contact Your
Local Molex Sales Office
Molex Application Tooling Group
2200 Wellington Court
Lisle, Illinois 60532
Tel: 630-969-4550
Fax: 630-505-0049
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
Table of Contents
SECTION
1.
General Description
2.
Start Up / Shut Down Procedures
3.
Message Fault Display and Maintenance
4.
Touch Screens and Troubleshooting
5.
Assembly Drawings, Electrical and Pneumatic Diagrams
6.
Connector Series Chart
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
Section 1
General Description
1.1.
Description
1.2.
Technical Specifications
1.3.
Applicable Products and Wires
1.4.
Delivery Check
1.5.
Cє Compliance
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
1.1
Description
The 62300-6200 APPLI-MATE™ (Rast 2.5) SemiAutomatic Terminator Machine, is designed to
terminate the APPLI-MATE™ (Rast 2.5) female
connector series (See Section 6) onto discrete
wire (0.22 mm2 or 0.38 mm2). This machine will
accommodate circuit size 2 through 20.
1.2
Technical Specifications
Power Specifications:
To function correctly, these fixtures require the
following services:
Electrical Service
115/220 VAC 50/60 HZ 1 Phase 2 AMPS
Pneumatic Service
6 BAR (85 psi) Minimum Clean, Dry and Filtered
Air Source
Pressure Gauge Settings
Main supply to machine - 6 BAR (85 psi)
1.3
Applicable Products And Wires
Connectors
Appli-Mate™ RAST 2.5 connector series 90871,
90872, 91716, 91717, and 92332. See
Connector Chart in Section 6.
Wires
Conductor: 0.22mm² or 0.38mm²
Insulation outer diameter: 1.60mm maximum
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
1.4 Delivery Check
Carefully remove this machine from its shipping
container and determine that the following items
are included in the package.
Order No.
62300-6200 Semi-Automatic Terminator
Machine for APPLI-MATE™
(Rast 2.5)
ATS-623006200 Instruction Manual
1.5
CE Compliance
Complies with the general health and safety
requirements in accordance with:
-Council Directive 98/37/EEC
-Council Directive 89/336/EEC and amended by 92/31/EEC
-Council Directive 73/23/EEC
This machinery has been designed and
manufactured in accordance with the
following transposed harmonised European
standards.
EN292: parts 1 and 2: 1991, Safety of Machinery - Basic
concepts, general principles for design.
EN294: 1992, Safety of Machinery - Safety distances to
prevent danger zones reached by the upper limbs.
EN349: 1993, Safety of Machinery - Minimum gaps to avoid
crushing of parts of the human body.
EN418: 1992, Safety of Machinery - Emergency stop
equipment, functional aspects - Principles for design.
EN60204 part 1: 1993, Safety of Machinery - Electrical
equipment of machines - Specification for general
requirements.
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RAST2.5 Semi-Automatic Terminator Machine
Section 2
Start-Up / Shut Down Procedures
2.1.
General Operation
2.2
Machine Operation and Process Flow
2.3
Operator Set Up And Functions
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
2.1
General Operation
2.1.1 Preliminary
1. Connect air supply to fixture. Use 6mm nylon air hose in the quick-fitting.
2. Turn on mains power Isolator.
3. Release Emergency-stop push buttons if necessary.
2.1.2 System Start-Up (When above conditions are met)
1.
2.
3.
4.
5.
Reset the power by pushing the Reset button.
Wait approximately 5 seconds for the air supply to reach operating pressure.
Home the sensor motor. See section 4.1 (screen 5).
Enter the circuit size. See section 4.1.
Press Start button.
2.1.3 Start-Up Following A Fault
1.
2.
3.
4.
5.
6.
Identify the fault on the touch screen.
Correct fault.
Reset the power by pushing the Reset button.
Wait approximately 5 seconds for the air supply to reach operating pressure.
Home the sensor motor.
Press Start button.
2.14
1.
2.
3.
4.
5.
Start-Up After An Emergency Stop Or Guard Interrupt
Release Emergency Stops or close guard doors.
Press Reset button on operator panel.
Wait approximately 5 seconds for the air supply to reach operating pressure.
Home the sensor motor.
Press Start button on operator panel
2.1.5 Start-Up After A Power Failure
1.
2.
3.
4.
5.
6.
Release Emergency Stops or close guard doors.
Press Reset button on operator panel.
Wait approximately 5 seconds for the air supply to reach operating pressure.
Home the sensor motor.
Enter the Circuit size.
Press Start button on operator panel
2.1.6 System Shut Down
1. Press the Emergency Stop button.
2. For extended periods of shutdown (i.e. Holidays), switch off the Mains Isolator.
CAUTION: NEVER OPERATE THIS FIXTURE WITHOUT GUARDS IN PLACE.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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2.2
Semi-Automatic Terminator Machine Operation and Process Flow
2.2.1 Connector Infeed
The strips of connectors are inserted into the adjustable locator. For operator instruction see section 2.3.
(operator set up and functions) The gripper then clamps the connectors and transports it into the next part of
the process, the cut station. This machine is designed to run one chain of connectors at a time. Connector
chains should not be stacked side-by-side.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
A
B
C
Clamping Cylinder
Knurled Screw to tighten/release
the adjustable gripper jaw
Clamp Screw
2.2.2 Connector Separate (Cut Loose)
1. In the automatic mode the connectors are transferred to the cut station by the connector feed cylinder.
2. The cut support track automatically moves in behind the first row of connectors.
3. The cut blade separates the first row of connectors from the chain, so it can be fed to the next station.
(The connector feed cylinder remains forward until after the cut.)
4. Note: Cutting loose happens simultaneously with termination.
A Cut Loose Blade
B Cut Support Track
C Connector Feed Cylinder
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Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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2.2.3 Connector Transfer
1. After a row of connectors has been separated they are transferred to the termination position.
2. After a connector has been inserted with wires and has been terminated the finished assembly is
transferred out of the terminating station while the newly separated connector enters.
3. The connector transfer and the
out feed are one motion.
A
B
C
D
Transfer Cylinder
Connecting Rod
Transfer Rod
Out feed Pawl
2.2.4 Wire Feed (Mask Tooling)
1. After the connector has been transferred from the cut station to the termination station the operator
manually inserts the wires into the connector.
2. This is aided by using a numbered plate (mask tooling) that slides down in front of the connector.
3. This slide centers the connector with location tooling on the mask tooling.
4. The operator can then use the mask
tooling to guide the wires into the
connector. See Section 2.3.4
(operator set up and functions)
A Mask Tooling (numbered plate)
B Manually inserted wires
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Release Date: 04-23-09
Revision Date: 06-18-09
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2.2.5 Wire Feed (Laser Sensor)
1. The Inserted wires push out a spring loaded pin at the back of the housing. A Laser Sensor senses the
movement of the pin.
2. According to the connector circuit size and corresponding program selected by the operator (See section
2.3.4) the machine detects when the correct amount of wires have been inserted successfully.
3. After all wires have been inserted
successfully, the machine automatically
terminates the connector.
A Laser Sensor
2.2.6 Termination Station
1.
2.
3.
4.
The connector is automatically terminated after all the wires have been inserted correctly.
The termination tool moves downwards and closes the connector, terminating the inserted wires.
At the same time a new row of connectors is being cut free from the chain.
The out feed pawl then removes the finished assembly to the end of the track.
A Open Connector
B Termination Tool
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Release Date: 04-23-09
Revision Date: 06-18-09
A Closed Connector
B Termination Tool
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RAST2.5 Semi-Automatic Terminator Machine
2.3
Operator Set-Up and Functions
2.3.1 Machine Run
To Power Up
1. Turn on main disconnect switch on electrical
cabinet door.
2. Touch screen will reset.
3. Laser sensor motor will automatically home
itself or request operator to press home
button.
To Set Up (Touch Screen)
1. Press “Manual”
2. Press “Set up”
3. Select circuit size (3 – 20)
4. Select positions of wires to be inserted and
choose the language.
5. Press “main” to return to start screen.
To Load Connector
1. Press “Manual “
2. Press “ Hsg feed open”
3. Press “Hsg cut support”
4. Feed connectors manually to touch face of
cut support blade. See section 2.3.3
5. Press “Hsg feed grip”
6. Press “Main”
7. Press “Load”
8. Terminator Machine will automatically feed
connectors to cut position.
To Start Run
1.
Press “ Start”
2.
The first connector will be cut the fed to
termination position.
3.
Mask tooling will lower
4.
Operator must manually insert wires into
connector. See section 2.3.4. Touch
screen will prompt operator position of
each wire.
To Correct An Incorrectly Inserted Wire
1. Cycle can be stopped if wrong wire is put
into wrong slot by pressing “REDO”
2. Mask tooling will rise allow removal of wire.
Note: other wires may fall out of the
connector and may need to be re-inserted.
3. Press “REDO” to restart cycle.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
Note: A wire must be inserted for functions
“STOP” or “REDO” to be available on the
touch screen.
For detailed explanations of touch screens see
SECTION 4.
2.3.2 Material Supply
1. The connectors are supplied in continuous
chains and can be connected or
disconnected at the trailing end of the chain.
2. A sensor detects when the machine is
running low on connectors.
3. The operator then connects the upper
housing of the chain in the machine into the
lower housing of the new chain. The
connector splicing tool should be used to
ensure the proper pre-load height.
The operator MUST remove the first part of
the connector at the beginning of the strip
of connectors to be fed into the machine.
The strips must begin with a complete
connector.
A Removed when loading an empty machine
2.3.3 Setting Up Connector Feed
1. When circuit size is changed the connector feed
must be set up.
2. Adjust the guide rail to suit the width of the
connectors. This can be set up to 20 positions.
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RAST2.5 Semi-Automatic Terminator Machine
3.
4.
5.
6.
The rail can be moved by opening the clamp
screws and simply sliding the rail lightly against
the connector chain as shown. The connectors
must be able to slide easily. Retighten the clamp
screws.
Loosen the knurled screw at the clamping
cylinder and slide the gripper jaw as far as
possible to the right.
Insert a strip of connectors into the machine
until they bottom out against the cut support
track.
Slide the gripper jaw to within approximately
2mm of the connectors and tighten the knurled
screw.
Select the circuit size with wire quantity and
position on the touch screen and start the
machine. (See Section 2.3.5)
move to the next position (prompted on the
touch screen).
4. The mask tooling has spring loaded inserts
which will keep the wires held in position until
the connector has been terminated. After the
wire is inserted, do not attempt to pull the wire
out as the clamp grip may damage the wire. If
an insertion error occurs, it is best to use the
REDO function.
A Spring Loaded Wire Clamp
B Fully inserted Wire
2.3.5 Termination Shut Height Adjustment
A
B
C
D
Cut Support Track
Guide Rail
Knurled Screw
Gripper Jaw
2.3.4 Wire Feed
1. The Operator must manually insert each
connector circuit size with corresponding
number of wires.
2. As explained in Section 2.2.5 the operator uses
a numbered guide as an aid to insert the wires
into the connector. The touch screen prompts
the operator to the number slot on the guide to
place each wire.
3. After the operator has correctly inserted the wire
at the correct position an audio tone will sound,
an LED will illuminate, and the operator can
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
A Shut Height Fine Adjustment Screw
1. The termination shut height may be easily
adjusted from the front of the machine.
2. Use a 24mm open-end wrench and an 8mm hex
key to finely adjust the shut height.
3. The adjustment screw is situated at the front of
machine as shown.
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RAST2.5 Semi-Automatic Terminator Machine
2.3.6 Program Selection (Circuit Size)
1. When circuit size (or number of wires loaded)
changes, the program must be changed on the
touch screen.
2. The following procedure must be followed when
setting up for a new program and circuit size as
well as setting up new connector feed. See
section 2.3.2.
3. On the touch screen:
a. From Ready to Run. Press “Manual”
b. From Manual. Press “Set Up”
c. From Set Up. “Enter circuit size.” Keypad
will appear. Select desired circuit size (3-20
circuit). Size will be displayed on circuit size
line.
d. From Set Up. Press “Next”
e. Select Wire Positions 1-10. Press the
number and Y and N will toggle in the box
above the number. Y= Wire Present, N= No
Wire. Ensure that unused circuit positions
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Release Date: 04-23-09
Revision Date: 06-18-09
have N. Press “Next” to set up Wire
Positions 11-20. Repeat for wires 11-20.
f. From Select Wire Positions. Press “Main” to
return to Ready to Run.
g. Press “Start” to run automatically. Press
“Load” to feed a housing into the feed track.
2.3.7 Machine Errors / Faults
The Operator is responsible for ensuring that
machine errors / faults are corrected immediately. If
the operator is unable to locate or resolve the fault,
they should seek assistance from the line
Technician.
See Section 4 for a full listing of faults.
2.3.8 Finished Product
The operator will ensure that the finished products
are removed from the end of the machine.
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RAST2.5 Semi-Automatic Terminator Machine
Section 3
Message Fault Display and Maintenance
3.1
Fault Displays
3.2
Maintenance
3.3
Perishable Tooling
3.4
Spare Parts
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
3.1
Fault Displays
3.1.1 Name and Fuctions
Name
Emergency Stop
(Red Mushroom knob
on yellow background)
Power On Lamp
(Green Lamp)
Reset Button
(Blue Switch)
Location
LH side of machine.
(Control Box)
Centre of machine.
(Control Box).
LH side of machine.
(Control Box)
Function
To stop fixture immediately
as well as isolating the mains power
and air from the fixture.
To Indicate that the
machine is ready to run.
To connect mains power
and air to the machine.
3.1.2 Description Of Indicators
Name
LED (Green)
Speaker
3.2
Indicator
Solid Green
Audible “beep”
Description
Wire inserted
Wire inserted
Maintenance
3.2 1 Cleaning
The RAST2.5 Semi-Automatic Terminator Machine should be cleaned at least once a day with a soft brush
to remove dust and debris.
CAUTION: Using compressed air to clean the Terminator is not recommended as debris could
become jammed in the tooling and/or come flying out at the operator
3.2.2 Lubrication
The press requires regular lubrication on a monthly basis. Place a small amount of lubricant with Teflon,
such as Permatex “Superlube”, on the sliding surfaces.
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your
Terminator or use this as a template to create you own schedule or use your company’s standard chart, if
applicable.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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3.2.3 Preventive Maintenance Chart
Time
Maintenance
Clean all tooling in the following areas
Daily
Weekly
Monthly
6 Months
3.3
Slides
Cylinders
Check out tooling for signs for of wear.
Check cutting and termination tools for signs of wear.
Check condition of slides.
Check that the air regulator is set to 6 Bar (85 psi).
Ensure all shock absorbers and stops are tight.
Wipe down all tooling in the following areas: slides, cylinders, and carriage rails.
Carry out Weekly PM.
Check slide for excessive play (tighten as necessary).
Check condition of all shock absorbers and stops.
Check out functionality of all sensors.
Check for air leaks, loose fittings, damaged airlines, and gauges.
Check General condition of all tooling.
Carry out Monthly Preventative Maintenance.
Perishable Parts
Customers are responsible for maintaining the The RAST 2.5 Semi-Automatic Terminator Machine.
Perishable parts are those parts that come in contact with the product and will wear out over time. Molex
recommends that all customers keep at least one set of the perishable tool kits in stock at all times. This
will reduce the amount of production down time. These parts are identified in the Parts List below.
Perishable Tooling List
Part No.
Description
Quantity
62300-6201
Housing Cut Blade
1
62300-6202
Termination Tool
1
62300-6203
Termination Support Blade
1
62300-6204 Termination Support Blade (side latches)
1
62300-6205
Wire Detect Pin
1
3.4
Spare Parts
Customers are responsible for maintaining the The RAST 2.5 Semi-Automatic Terminator Machine. Spare
parts are available. Moving and functioning parts can be damaged or wear out over time and will require
replacement. See assembly drawings and parts lists in Section 5 for additional detail.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Section 4
Touch Screens and Troubleshooting
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
Touch Screens
door has been closed. Release the Emergency Stop
button and press the blue reset button on the main
Panel.
Screen 1
Start Up Screen
Screen 4
Safety Guard Open Screen
This screen appears after the machine has been
powered up.
It is only an information screen.
This screen is displayed when the safety guard is
open. Close the guard and press the blue reset
button on the main panel.
Screen 2
Ready to Run Screen
Screen 5
Sensor must be Homed Screen
This screen is displayed when the machine is
stopped and there are no fault conditions. It has 3
buttons located on the bottom.
START: This button starts the machine.
LOAD:When there is no housing in the feed track,
press this button to automatically move a
part into the feed track.
MANUAL:Selects manual mode and changes the
screen to the Manual #1 [Screen 30].
This is displayed after the machine has been reset.
The stepper motor that drives the laser sensor must
be homed after a power loss or Emergency Stop to
ensure it is in the correct position to detect the wires.
Press the HOME button and it will home
automatically. When the sensor reaches the home
position, the Ready to Run screen will be displayed.
Screen 3
Emergency Stop Screen
Screen 6
Running Screen
This screen is displayed when the Emergency Stop
button has pressed. It also appears after power up
and after the Safety Guard Open screen, when the
Doc: No: ATS-623006200
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Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when the machine is
running in automatic mode.
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Parts Made:Displays how many parts have been
made in the current batch.
Insert Wire into Position: Displays the position
where the current wire is to be inserted.
STOP:This button stops the automatic mode. The
operator must finish inserting all wires into
the connector and terminate the connector
before the end of cycle is reached.
REDO:This button allows the operator to correct an
error on the existing connector. The mask
tooling will go up, the wire(s) can be removed
and the sensor motor will go to home
position. Screen 9 will be displayed when
this button is pressed.
This screen is displayed after the Home Sensor
Button has been pressed on Screen 5. When the
sensor reaches the home position the Ready to Run
Screen will be displayed.
Screen 7
Waiting to Stop Screen
This screen appears after REDO has been
pressed on either Screen 6 or 7. When all the
wires have been removed, press REDO to return
to Screen 6 or 7.
Screen 9
Redo Screen
Screen 10
Conveyor Low Level Fault Screen
This screen is displayed after the stop button has
been pressed and before the current cycle has been
completed.
Parts Made:Displays how many parts have been
made in the current batch.
Insert Wire into Position:Displays the position
where the current wire is to be inserted.
REDO:This button allows the operator to correct an
error on the existing housing. The mask
tooling will go up, the wires can be removed
and the sensor motor will go to home
position. Screen 9 will be displayed when
this button is pressed.
This screen is displayed when the connector
conveyor level is low. Join another chain to the
existing chain and press the CLEAR button to
continue.
Screen 11
Housing Cut Support not Out Fault Screen
Screen 8
Sensor is Homing Screen
This screen is displayed when the Housing Cut
Support Cylinder fails to activate sensor B0.05.
Check to see if the tooling jammed or if something is
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Release Date: 04-23-09
Revision Date: 06-18-09
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stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 14
Housing Feed not Forward Fault Screen
Screen 12
Housing Cut Support Not In Fault Screen.
This screen is displayed when the Housing Cut
Support Cylinder fails to activate sensor B0.06.
Check to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 13
Housing Feed not Back Fault Screen
This screen is displayed when the Housing Feed
Cylinder fails to activate sensor B0.10. Check to
see if the tooling jammed or if something is stopping
the cylinder from completing its stroke. Clear the
fault and press CLEAR button.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when the Housing Feed
Cylinder fails to activate sensor B0.11. Check to
see if the tooling jammed or if something is stopping
the cylinder from completing its stroke. Clear the
fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 15
Housing Feed Gripper not Closed Fault
Screen
This screen is displayed when the Housing Feed
Gripper Cylinder fails to activate sensor B0.09.
Check to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
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Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 16
Housing Feed Gripper Cylinder not Open Fault
Screen
Screen 18
Housing Stick Feed not Forward Fault Screen
This screen is displayed when the Housing Feed
Gripper Cylinder fails to deactivate sensor B0.09.
Check to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 17
Housing Stick Feed not Back Fault Screen
This screen is displayed when the Housing Stick
Feed Cylinder fails to activate sensor B0.07. Check
to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when the Housing Stick
Feed Cylinder fails to activate sensor B0.08. Check
to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 19
Mask Tooling not Up Fault Screen
This screen is displayed when the Mask Tooling
Cylinder fails to activate sensor B1.00. Check to
see if the tooling jammed or if something is stopping
the cylinder from completing its stroke. Clear the
fault and press CLEAR button.
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Page 22 of 70
RAST2.5 Semi-Automatic Terminator Machine
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 22
Termination Tooling not Down Fault Screen
Screen 20
Mask Tooling not Down Fault Screen
This screen is displayed when the Mask Tooling
Cylinder fails to activate sensor B1.01. Check to
see if the tooling jammed or if something is stopping
the cylinder from completing its stroke. Clear the
fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
This screen is displayed when the Termination
Tooling Cylinder fails to activate sensor B1.03 .
Check to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
opening the guard door or disconnecting the air
supply. If any of these are done their respective
faults (“Emergency Stop”, “Safety Guard Open”, or
“Air Pressure Low”) will take precedence on the
display.
Screen 23
Air Pressure Low Fault Screen
Screen 21
Termination Tooling not Up Fault Screen
This screen is displayed when the Termination
Tooling Cylinder fails to activate sensor B1.02.
Check to see if the tooling jammed or if something is
stopping the cylinder from completing its stroke.
Clear the fault and press CLEAR button.
This screen is displayed when the Air Pressure
coming to the Machine is Low. Check the folowing:
1. Factory Air Pressure is OK.
2. Air is connected to the machine.
3. Air Isolating Valve is turned on.
4. Air Pressure is set to 6.0 bar (85 psi)
5. Air Safety valve is on.
6. Air Leaks.
Air may have to be removed from the machine to
clear the fault either by pressing Emergency Stop,
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 23 of 70
RAST2.5 Semi-Automatic Terminator Machine
Screen 31
Manual Screen #2
Screen 30
Manual Screen #1
This screen is displayed when Manual has been
selected from the Ready to Run Screen or PREV
has been selected from the Manual #2 Screen.
Hsg Cut Support Button: This button allows
manual operation of the Housing Cut Support
Cylinder. Pressing the button once will extend the
cylinder (out); pressing it again will retract the
cylinder (in). The text on the button will change
between IN and OUT as the button is pressed.
Hsg Stick Feed Button: This button allows manual
operation of the Housing Stick Feed Cylinder.
Pressing the button once will extend the cylinder
(out); pressing it again will retract the cylinder (in).
The text on the button will change between
FORWARD and BACK as the button is pressed.
The cylinder can only move Forward if the Housing
Cut Support is out and can only move Back if the
Housing Feed Gripper is open.
Hsg Feed Grip Button: This button allows manual
operation of the Housing Feed Gripper Cylinder.
Pressing the button once will allow the cylinder to
move open, pressing it again will return the cylinder
to the closed position. The text on the button will
change between OPEN and CLOSE as the button is
pressed.
NEXT: Changes the screen to the Manual #2
Screen
SET UP: Selects Set Up mode and changes the
screen to the Set Up #1 [Screen 40].
MAIN: Select Automatic mode and changes the
screen to Ready to Run [Screen 2].
CLEAR: Clears any faults.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when the NEXT button is
pressed on Manual Screen #1.
Hsg Feed Button:This button allows manual
operation of the Housing Feed Cylinder. Pressing
the button once will allow the cylinder to move
forward, pressing it again will return the cylinder to
the back position. The text on the button will change
between FORWARD and BACK as the button is
pressed. The cylinder can move FORWARD only
when the Mask tooling is up.
Mask Tooling Button:This button allows manual
operation of the Mask Tooling Cylinder. Pressing
the button once will allow the cylinder to move up,
pressing it again will return the cylinder to the down
position. The text on the button will change between
UP and DOWN as the button is pressed.
Termination Button:This button allows manual
operation of the Termination Cylinder. Pressing the
button once will allow the cylinder to move down,
pressing it again will return the cylinder to the up
position. The text on the button will change between
DOWN and UP as the button is pressed. The
cylinder can move Down only when the Housing
Feed is back.
PREV: Changes the screen to Manual Screen #1.
SET UP:Selects Set Up mode and changes the
screen to the Set Up #1 [Screen 40].
MAIN: Select Automatic mode and changes the
screen to Ready to Run [Screen 2].
CLEAR: Clears any faults.
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Page 24 of 70
RAST2.5 Semi-Automatic Terminator Machine
Screen 40
Set Up #1 Screen
Screen 41
Set Up Screen #2
This screen is displayed when the SET UP button is
pressed on the Manual Screens or PREV has been
selected from the Set Up #2 screen.
This screen is displayed when the NEXT button
is pressed on the Set Up #1 Screen.
CIRCUIT SIZE: This displays the current circuit size
of the connectors being processed.
SELECT WIRE POSITIONS: This allows selection
of wires (1-10 only) that are to be loaded in the
connector. Pressing the number of the wire position
will either select or deselect the presence of a wire
in that position. The current status of that position is
displayed above the number [Y = wire present, N =
no wire].
ENTER CIRCUIT SIZE: This button allows the
circuit size of the connector to be entered. When
the button is pressed a pop-up screen [Screen
65001] will appear. When the ENTER button on the
pop-up Screen is pressed, the circuit size will be
displayed on the button. Only values between 3 and
20 will be accepted by the display.
Parts Made: Displays how many assemblies have
been made in the current batch.
NEXT: Changes the screen to the Set Up #2 Screen
RESET_COUNTER Button: Resets the value of
Parts Made to zero.
MAIN: Select Automatic mode and changes the
screen to Ready to Run [Screen 2].
For circuit sizes below 20 please ensure that all
positions above the current size are status “N”.
NEXT: Changes the screen to Set Up Screen #3
(Screen 42)
PREV: Changes the screen to Set Up Screen #1
(Screen 40)
MAIN: Changes the screen to Ready to Run Screen
(Screen 2)
Screen 42
Set Up Screen #3
Screen 65001
Pop Up Screen
This screen appears when the Enter circuit Size
Button has been pressed on Screen 40. Enter the
desired circuit size on the “calculator” screen and
press ENT. Only values between 3 and 20 will be
accepted.
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when NEXT button is
pressed on the Set Up #2 Screen.
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Page 25 of 70
RAST2.5 Semi-Automatic Terminator Machine
SELECT WIRE POSITIONS: This allows selection
of wires (11-20 only) that are to be loaded in the
connector. Pressing the number of the wire position
will either select or deselect the presence of a wire
in that position. The current status of that position is
displayed above the number (Y = wire present, N =
no wire).
For circuit sizes below 20 please ensure that
all positions above the current size are N.
NEXT: Changes the screen to Set Up Screen #4
(Screen 43)
PREV: Changes the screen to Set Up Screen #2
(Screen 41)
MAIN: Changes the screen to Ready to Run
Screen (Screen 2)
Screen 43
Set Up Screen #4
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
This screen is displayed when the NEXT button is
pressed on the Set Up #3 Screen.
SELECT LANGUAGE. This allows language
selection for the touch screen messages.
When the screens are displayed in English pressing
TURKISH will automatically redisplay the screen in
Turkish. All the Turkish screens have the exact
same layout and functions as the English screens.
When the screens are displayed in Turkish pressing
ENGLISH will automatically redisplay the screen in
English.
PREV: Changes the screen to Set Up Screen #3
(Screen 42)
MAIN: Changes the screen to Ready to Run
Screen (Screen 2)
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Page 26 of 70
RAST2.5 Semi-Automatic Terminator Machine
Section 5
Assembly Drawings, Electrical and Pneumatic Diagrams
5.1
Assembly Drawings
5.2
Electrical Drawings
5.3
Pneumatic Drawings
5.1 Main Assembly
Main Assembly 62300-6200
Item Order No.
Description
Qty.
1
62300-6206
Table Top
1
2
62300-6207
Termination Track Assembly
1
3
62300-6208
Frame Assembly
1
4
62300-6209
Toggle Joint Assembly
1
5
62300-6210
Infeed Table Assembly
1
6
62300-6211 Cut and Termination Slide Assembly 1
7
62300-6212
Infeed Gripper Assembly
1
8
62300-6213
Laser Sensor Assembly
1
9
62300-6214
Out-Feed Pawl Assembly
1
10 62300-6215
Mask Tooling Assembly
1
11 62300-6216
IOP Box Assembly
1
12 62300-6217
Guard
1
13 62300-6218
Polycarb Guard
1
14 62300-6219
Guard
1
15 62300-6220
Guard
1
16 62300-6221
Cabinet Skirt
1
17 62300-6222
Stainless Guard
1
18 62300-6223
Polycarb Guard
1
19 62300-6224
Hinged Guard
1
20 62300-6225
Hinged Guard Support
1
21 62300-6226
Proximity Switch
1
22 62300-6227
Prox Pivot Pin
1
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 27 of 70
RAST2.5 Semi-Automatic Terminator Machine
Main Assembly
3
6
7
10
21
22
5
2
1
Doc: No: ATS-623006200
Revision: B
8
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 28 of 70
RAST2.5 Semi-Automatic Terminator Machine
9
16
11
17
12
18
15
19
20
14
13
4
7
Main Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 29 of 70
RAST2.5 Semi-Automatic Terminator Machine
Termination Track Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Doc: No: ATS-623006200
Revision: B
Terminator Track Assembly 62300-6207
Order No.
Description
Qty.
62300-6228
Termination Track
1
62300-6229
Entry Cover
1
62300-6230
Exit Cover
1
62300-6231
Wire Guide Support
1
62300-6232
Slide Cover Plate
1
62300-6233
Wire Detect Pin Slide
1
62300-6234
Spring Block
1
62300-6205
Wire Detect Pin
2
62300-6235
Wire Detect Lever
2
62300-6236
Wire Detect Trigger Pin
2
62300-6237
Spring Support Plate
1
62300-6238
Pivot Block
1
62300-6239
Pivot Pin
2
62300-6240
Laser Reflect Plate
1
62300-6241
Termination Brake
1
62300-6242
Pivot Pin
2
N/A
C-Spring Entex #913
4
N/A
C-Spring Entex #3100
20
REF
Customer Product- Rast 2.5 1
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 30 of 70
RAST2.5 Semi-Automatic Terminator Machine
11
16
2
1
4
15
9
4
19
5
9
A-A
5
13
12
6
8
19
7
11
18
A
13
A
9
6
10
Termination Track Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 31 of 70
RAST2.5 Semi-Automatic Terminator Machine
Frame Assembly
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
Frame Assembly 62300-6208
Order No.
Description
Qty
62300-6243
Left Frame Upright
1
62300-6244
Right Frame Upright
1
62300-6245
Front Cover Plate
1
62300-6246
Right Track Upright
1
62300-6247
Left Track Upright
1
62300-6248
THK Slide Bkt.
2
62300-6249
Back Frame Upright
1
62300-6250
Top Plate
1
62300-6251
Gusset
2
62300-6252
Termination Adjust Plate
1
62300-6253
Top Front Plate
1
62300-6254
Front Cover
1
62300-6255
Guide Plate
1
62300-6256
Infeed Table Mtg. Plate
2
62300-6257
Cylinder Mtg. Plate
1
62300-6258
Cut Loose St Support Plate
1
62300-6259
Termination Slide Mtg. Plate
1
62300-6260
Rear Hinged Cover
1
N/A
Transfer Cylinder- Festo -DSNU 20-150-PPV-A-S10 1
N/A
Foot Mtg.- Festo -HBN-20-25x2
2
N/A
Floating Joint- Festo -2062_FK_M8
1
N/A
Lifting Eye Bolt- Misumi -SCHI16
1
N/A
Stepped Hinge- Misumi -HHSD5
1
N/A
Hard Stop- Misumi -ANB 16-45
1
N/A
Nut- Misumi -ANN 16
1
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 32 of 70
RAST2.5 Semi-Automatic Terminator Machine
23
19
18
7
12
9
17
8
3
4
24
2
11
5
6
15
6
22
4
25
16
10
13
1
20
21
14
Frame Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 33 of 70
RAST2.5 Semi-Automatic Terminator Machine
Toggle Joint Assembly
Item
1
2
3
4
5
6
7
8
9
12
13
14
15
16
17
Doc: No: ATS-623006200
Revision: B
Toggle Joint Assembly 62300-6209
Order No.
Description
Qty.
62300-6261
Fixed Pivot Pin
1
62300-6262
Cylinder Pivot Block
1
62300-6263
Fixed Pivot Block
2
62300-6264
Fixed Link Arm
1
62300-6265
Moving Link Arm
1
62300-6266
Toggle Joint
1
62300-6267
End Plate
1
62300-6268
Toggle Joint Pivot Pin
1
62300-6269
Brass Washer
1
N/A
Flange Bushing- Oilite -AMF1521 25
2
N/A
Straight Bushing- Oilite -AMC1215-16
2
N/A
Compact Cylinder- Festo -ADN-80-40-A-P-A 1
N/A
Swivel Flange- Festo -SNCB-80
1
N/A
Straight Bushing- Oilite -AMC1620 12
2
N/A
M16 Nut
1
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 34 of 70
RAST2.5 Semi-Automatic Terminator Machine
Toggle Joint Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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RAST2.5 Semi-Automatic Terminator Machine
In-Feed Table Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Doc: No: ATS-623006200
Revision: B
In-Feed Table Assembly 62300-6210
Order No.
Description
Qty.
62300-6270
In-feed Table
1
62300-6271
In Feed Front Plate
1
62300-6272
Adjustment Side Guide
1
62300-6273
Fixed Side Guide
1
62300-6274
Push Bar Mtg. Block
1
62300-6275
Tie Rod Connect Block
1
62300-6276
Push Bar
1
62300-6277
Cut Station Track Section
1
62300-6278
Gateway Track
1
62300-6279
Infeed Ramp
1
62300-6280
Track Spacer
1
62300-6281
Cylinder Mtg. Plate
1
62300-6282
Push Bar End Stop
1
62300-6283
Cylinder Pos Block
2
62300-6284
Rail Support Block
2
N/A
Cylinder- Festo - DZF-12-70-A-P-A
1
N/A
Floating Joint- Festo -2061 FK-M6-(0;0)
1
N/A
Rail and Carriage- THK- RSH15ZMUU+270L 1
REF
Customer Product-RAST 2.5
1
N/A
Knob- Ganter Griff -GN 6335.4-TE-32-M6-25 1
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 36 of 70
RAST2.5 Semi-Automatic Terminator Machine
In-Feed Table Assembly
\
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 37 of 70
RAST2.5 Semi-Automatic Terminator Machine
Cut and Termination Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
---
Doc: No: ATS-623006200
Revision: B
Cut and Term Slide Assembly 62300-6211
Order No.
Description
Qty.
62300-6285
Cut and Termination Tooling Plate
1
62300-6286
Toggle To Slide Linkage
1
62300-6201
Housing Cut Blade
1
62300-6202
Termination Tool
1
62300-6287
Toggle Joint Pin
1
62300-6288
Cut and Termination Tooling Key
1
62300-6289
Brass Washer
2
62300-6203
Termination Support Blade
1
62300-6290
Termination Insert
1
N/A
Rail and Carriage- THK -SRS15WMUU+190L 1
N/A
Bush- Oilite -AMC1620 12
2
62300-6204
Termination Support Blade-Latches
1
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 38 of 70
RAST2.5 Semi-Automatic Terminator Machine
Cut and Termination Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 39 of 70
RAST2.5 Semi-Automatic Terminator Machine
In-Feed Gripper Assembly
Item
1
2
3
4
5
6
7
8
9
10
Doc: No: ATS-623006200
Revision: B
In-Feed Gripper Assembly 62300-6212
Order No.
Description
Qty.
62300-6291
Infeed Cylinder Mtg. Plate
1
62300-6292
Fixed Clamp Plate
1
62300-6293
Adjustable Clamp Plate
1
62300-6294
Clamp Cylinder Plate
1
62300-6295
Infeed Moving Clamp
1
62300-6296
Cylinder Spacer Block
1
62300-6297
Cylinder Spacer Block
1
N/A
Thumbscrew- Ganter Griff -DIN 653-M6-16 1
N/A
Cylinder- Festo- DFM-16-20-P-A-GF
1
N/A
Compact Cylinder- Festo -ADNGF-16-5-P-A 1
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 40 of 70
RAST2.5 Semi-Automatic Terminator Machine
Laser Sensor Assembly
Laser Sensor Assembly 62300-6213
Item Order No.
Description
Qty.
1
62300-6298
Mounting Feet
2
2
62300-6299
Slide Mtg. Plate
1
3
62300-6401
Sensor Mtg. Block
1
4
N/A
Festo Unit (Items 7 thru 10)
REF
5
N/A
Location Pins- Festo -150928 ZBS-5
2
6
N/A
Sensor- Omron - ZX-LD40
1
7
N/A
Festo -KSE-15-22-D04-D05
1
8
N/A
Festo -MTR-ST-42-48S-AA
1
9
N/A
Festo -MTR-FL30-ST42 FLANGE
1
10
N/A
Festo -DGE-12-100-ZR-LV-RV-GK-KF-KG 1
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 41 of 70
RAST2.5 Semi-Automatic Terminator Machine
Out-Feed Pawl Assembly
Item
1
2
3
4
5
6
8
9
10
11
12
13
Out-Feed Pawl Assembly 62300-6214
Order No.
Description
Qty.
62300-6402
Out-Feed Pawl Mtg. Plate
1
62300-6403
Out-Feed Pawl Body
1
62300-6404
Out-Feed Pawl Body
1
62300-6405
Out-Feed Pawl Adjust Block
1
62300-6406
Pawl Pivot Pin
1
N/A
Rail and Carriage- THK -RSH15ZMUU+190L
1
N/A
Floating Joint- Festo -2061 FK-M6-(0;0)
2
N/A
Tension Spring- Entex - #521 TENSION
1
N/A
Spring Post- Misumi -BSPL4-25
1
Nut- Misumi -ANN 4
1
N/A
Hard Stop- Misumi -ANB 4-20
1
N/A
Hexagonal Post- Misumi - LSBL10-263-F10-M6-N6-FC 1
N/A
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 42 of 70
RAST2.5 Semi-Automatic Terminator Machine
Out-Feed Pawl Assembly
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
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Page 43 of 70
RAST2.5 Semi-Automatic Terminator Machine
Wire Mask Tooling
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Doc: No: ATS-623006200
Revision: B
Wire Mask Tooling 62300-6215
Order No.
Description
Qty.
62300-6407
Mask Tooling Slide Plate
1
62300-6408
Mask Tooling
1
62300-6409
Spring Retaining Block
1
62300-6410
Cable Gripper
1
62300-6411
Adjustable Comb Tooling
1
62300-6412
Wire Detect Trigger Pin
2
62300-6413
Thumbscrew Washer
1
62300-6414
Cylinder Clevis
1
62300-6415
Floating Joint
1
62300-6416
Gripper Pivot Pin
1
Rail and Carriage- THK -RSH9WZMUU+80L 1
N/A
Cylinder- Festo -DMM-20-20-P-A
1
N/A
Thumbscrew- Ganter Griff -DIN 464-M4-12
1
N/A
Compression Spring- Entex - #3016
20
N/A
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 44 of 70
RAST2.5 Semi-Automatic Terminator Machine
Wire Mask Tooling
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 45 of 70
RAST2.5 Semi-Automatic Terminator Machine
IOP Box Assembly
Item
1
2
IOP Box Assembly 62300-6216
Order No.
Description
62300-6417
IOP Box
62300-6418
Lexan Label
Qty.
1
1
1
OMRON HMI SCREEN
2
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 46 of 70
RAST2.5 Semi-Automatic Terminator Machine
5.2
Electrical Parts List
Manufacturer
Allen-Bradley
Description
Qty
440N-S32022
1
CPM2A-60CDT1-D
1
NT2S-CN212V1
1
NT3S-ST126BE
1
Omron
S8VS-12024
1
ZXLD40
1
ZXLDA41
1
209-501Customise cards
20
Wago
280-402
100
280-520
50
ITW
DE9SF
1
Moeller
TO-2-1/EZ
1
ZB2BZ101
1
ZB2BZ102
1
ZB2BS54
1
Telemecanique
ZB2BE102
1
ZB2BA6
1
ZB4BVB3
1
ZB4BV033
1
MH
MHDM-9-K
1
Merlin Gerin
C60HD102
1
CML
19210351 LED Green
1
PILZ
774310 PNOZ X3 24VAC 24VDC Safety Relay
1
Radionics
622-1449
1
AS1001F-04 Speed Control
10
SMC Pneumatics
KGL04-M5 - elbows
10
150387 SIEN-M8B-PS-S-L Proximity Switch,M8
1
150857 SME-8-S-LED-24 Proximity Switch
11
151687 MSSD-EB Plug Socket
2
153344 QSML-4 Fitting
5
153347 QSML-4H Fitting
5
159421 SIM-M8-3GD-5-PU Proximity Switch Socket, Straight
13
159423 SIM-M8-3WD-5-PU Proximity Switch Socket, Right Angle 1
Festo Ltd
161419 UC-1/8 Silencer
2
163142 CPE18-M1H-5L-1/4
1
164274 PEV-1/4-WD-LED-24 Angled Socket
1
165004 UC-1/4 Silencer
2
175095 SMBR-8-20 Mounting Kit
2
185781 LFR-1/4-D-MINI-KG Servis Combination
1
193740 DGE-12-100-ZR-LK-KG-KF-GK Toothed Belt Axis
1
2061 FK-M6
2
2061 FK-M6
1
2062-FK-M8
1
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 47 of 70
RAST2.5 Semi-Automatic Terminator Machine
Manufacturer
Festo Ltd
Description
525675 CPV-SC-MP-VI Valve Terminal
[80P-10-1MS-PF-N-SLG-MJJ3MLL+CP]
525911 SMT-8F-24V-K7,5-OE Proximity Switch
530059 MTRE-ST-42-48S-AA Stepper Motor
530079 MTR-FL30-ST42 Motor Flange
530084 KSE-15-22-D04-D05 Coupling
ADN-80-40-A-P-A
ADNGF-16-5-P-A
DFM-16-20-P-A-GF
DMM-20-20-P-A
DSNU 20-150-PPV-A-S10
DZF-12-70-A-P-A
SIEN-M5B-PS-S-L
SNCB-80
Qty
1
2
1
1
1
1
1
1
1
1
1
1
1
Commercial Hardware
Manufacturer
FHB
Description
Qty
600 X 400 X 200 Cabinet
1
Entex No 3016
50
Entex No 913
10
Entex No 3022
50
Kato-Entex
Entex No 3096
50
Entex No 3100
50
Entex No 3302
1
ANB16-45
1
BSPL4-25
1
HHKS100
1
Misumi
HHKST100
1
HHSD5
1
LBRFNF6-283-10-PC-QC 1
SCHI16
1
2SRS15WMUU+190L
1
SRS 9WM UU +80L
1
THK
RSH15ZMUU+230L
1
RSH15ZMUU+270L
1
MQB 1.59 63 )
27
Royal Diversified Products Inc.
MQB 1.60 X 63 )
27
DIN 464-M4-12
1
DIN 464-M4-20
1
TED Ltd
DIN 653 M6-16
1
GN 6335.4-TE-32-M6-25
2
GN 6335.4-TE-32-M6-45
2
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 48 of 70
RAST2.5 Semi-Automatic Terminator Machine
5.2
Electrical Drawings
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 49 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 50 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 51 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 52 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 53 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 54 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 55 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 56 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 57 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 58 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 59 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 60 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 61 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 62 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 63 of 70
RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 64 of 70
RAST2.5 Semi-Automatic Terminator Machine
5.3 Pneumatic Diagrams
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
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RAST2.5 Semi-Automatic Terminator Machine
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 66 of 70
RAST2.5 Semi-Automatic Terminator Machine
Section 6
Connector Series Chart
Products: 2.50mm (.098") Pitch Appli-Mate™ RAST 2.5 IDT Connector Assemblies 2 to 20 Circuits.
Connector
Circuit Size
Series No.
3
4
5
6
90871
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2
3
90872
4
5
6
7
8
2
91491
3
4
5
Doc: No: ATS-623006200
Revision: B
Connector Assembly Order No.
90871-0001
90871-0018
90871-0041
90871-0501
90871-0508
90871-0542
90871-1001
90871-1008
90871-1501
90871-1508
90871-1515
90871-1522
90871-1529
90871-2001
90871-2009
90871-2501
90871-2508
90871-3001
90871-3501
90871-4001
90871-4501
90871-5001
90871-5501
90871-6001
90871-6501
90871-7001
90871-7501
90871-8001
90871-8501
90872-0002
90872-0009
90872-0016
90872-0023
90872-1001
90872-1009
90872-2001
90872-2008
90872-3001
90872-4001
90872-5001
90872-6001
91491-0002
91491-0003
91491-0263
91491-0004
91491-0005
90871-0002
90871-0019
90871-0042
90871-0502
90871-0509
90871-0677
90871-1002
90871-1009
90871-1502
90871-1509
90871-1516
90871-1523
90871-1751
90871-2002
90871-2251
90871-2502
90871-2509
90871-3002
90871-3502
90871-4002
90871-4751
90871-5002
90871-5751
90871-6002
90871-8751
90872-0003
90872-0010
90872-0017
90872-0024
90872-1002
90872-1010
90872-2002
90872-2009
90871-0013
90871-0020
90871-0044
90871-0503
90871-0530
90871-0678
90871-1003
90871-1251
90871-1503
90871-1510
90871-1517
90871-1524
90871-1752
90871-2004
90871-2253
90871-2503
90871-2751
90871-3003
90871-3503
90871-4251
90871-0014
90871-0021
90871-0251
90871-0504
90871-0538
90871-0679
90871-1004
90871-0015
90871-0022
90871-0252
90871-0505
90871-0539
90871-0751
90871-1005
90871-0016
90871-0024
90871-0253
90871-0506
90871-0540
90871-0752
90871-1006
90871-0017
90871-0034
90871-1504
90871-1511
90871-1518
90871-1525
90871-1753
90871-2005
90871-1505
90871-1512
90871-1519
90871-1526
90871-1506
90871-1513
90871-1520
90871-1527
90871-1507
90871-1514
90871-1521
90871-1528
90871-2504
90871-2752
90871-3004
90871-3751
90871-2505 90871-2506 90871-2507
90871-2753
90871-3251 90871-3256
90871-3752 90871-3753
90871-0507
90871-0541
90871-0755
90871-1007
90871-2006 90871-2007 90871-2008
90871-5003 90871-5004 90871-5005
90871-6251
90872-0004
90872-0011
90872-0018
90872-0351
90872-1003
90872-1011
90872-2003
90872-2010
90872-0005
90872-0012
90872-0019
90872-0352
90872-1004
90872-1501
90872-2004
90872-2011
90872-0006
90872-0013
90872-0020
90872-0353
90872-1005
90872-0007
90872-0014
90872-0021
90872-0354
90872-1007
90872-0008
90872-0015
90872-0022
90872-0501
90872-1008
90872-2005 90872-2006 90872-2007
90872-5002
91491-0022 91491-0042 91491-0062
91491-0023 91491-0043 91491-0063 91491-0143 91491-0203 91491-0243
91491-0044 91491-0104 91491-0144 91491-0304 91491-0344
91491-0045 91491-0305 91491-0345 91491-0405 91491-0445
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 67 of 70
RAST2.5 Semi-Automatic Terminator Machine
Connector
Circuit Size
Series No.
6
7
8
9
10
11
91491
12
13
14
15
16
17
18
3
4
5
6
91716
7
8
9
10
11
12
13
14
15
16
17
18
19
20
91717
2
Doc: No: ATS-623006200
Revision: B
Connector Assembly Order No.
91491-0006
91491-0007
91491-0008
91491-0009
91491-0010
91491-0950
91491-0011
91491-1051
91491-0012
91491-1112
91491-0013
91491-0014
91491-0015
91491-0016
91491-0017
91491-0018
91716-0001
91716-0018
91716-0034
91716-0501
91716-0530
91716-0544
91716-1001
91716-1008
91716-1015
91716-1501
91716-1509
91716-1516
91716-1523
91716-1531
91716-2001
91716-2009
91716-2016
91716-2501
91716-2508
91716-3001
91716-3008
91716-3501
91716-4001
91716-4501
91716-5001
91716-5501
91716-6001
91716-6501
91716-7001
91716-7501
91716-8001
91716-8501
91717-0002
91717-0009
91717-0016
91717-0023
91717-0030
91491-0046
91491-0047
91491-0048
91491-0049
91491-0050
91491-0506
91491-0607
91491-0208
91491-0509
91491-0210
91491-0546
91491-0647
91491-0248 91491-0708 91491-0748 91491-2048
91491-0549 91491-0809 91491-0849
91491-0250 91491-0310 91491-0350 91491-0910
91491-0051 91491-0511 91491-0551 91491-0611 91491-0651 91491-1011
91491-0052
91491-1152
91491-0053
91491-0054
91491-0055
91491-0056
91491-0057
91491-0058
91716-0002
91716-0019
91716-0041
91716-0502
91716-0538
91716-0545
91716-1002
91716-1009
91491-0412 91491-0452 91491-0612 91491-0652 91491-0852
91491-1213
91491-1314
91491-0215
91491-1516
91491-1617
91491-1718
91716-0013
91716-0020
91716-0042
91716-0503
91716-0539
91716-0546
91716-1003
91716-1010
91491-1253
91491-1354
91491-0255
91491-1556
91491-1657
91491-1758
91716-0014
91716-0021
91716-0043
91716-0504
91716-0540
91716-0677
91716-1004
91716-1011
91716-1502
91716-1510
91716-1517
91716-1524
91716-1532
91716-2002
91716-2010
91716-2017
91716-2502
91716-2509
91716-3002
91716-3009
91716-3502
91716-1503
91716-1511
91716-1518
91716-1525
91716-1534
91716-2004
91716-2011
91716-2018
91716-2503
91716-2510
91716-3003
91716-1504
91716-1512
91716-1519
91716-1526
91716-1535
91716-2005
91716-2012
91716-2019
91716-2504
91716-2511
91716-3004
91491-1415 91491-1455
91716-0015
91716-0022
91716-0044
91716-0505
91716-0541
91716-0678
91716-1005
91716-1012
91716-0016
91716-0023
91716-0045
91716-0506
91716-0542
91716-0679
91716-1006
91716-1013
91716-0017
91716-0024
91716-0046
91716-0507
91716-0543
91716-1505
91716-1513
91716-1520
91716-1527
91716-1536
91716-2006
91716-2013
91716-1506
91716-1514
91716-1521
91716-1528
91716-1537
91716-2007
91716-2014
91716-1507
91716-1515
91716-1522
91716-1529
91716-1007
91716-1014
91716-2008
91716-2015
91716-2505 91716-2506 91716-2507
91716-2512 91716-2513 91716-2514
91716-3005 91716-3006 91716-3007
91716-3503 91716-3504
91716-4502 91716-4503 91716-4504 91716-4505
91716-5002 91716-5003
91716-6002
91717-0003
91717-0010
91717-0017
91717-0024
91717-0031
91717-0004
91717-0011
91717-0018
91717-0025
91717-0032
Release Date: 04-23-09
Revision Date: 06-18-09
91717-0005
91717-0012
91717-0019
91717-0026
91717-0033
91717-0006
91717-0013
91717-0020
91717-0027
91717-0035
91717-0007
91717-0014
91717-0021
91717-0028
91717-0036
UNCONTROLLED COPY
91717-0008
91717-0015
91717-0022
91717-0029
91717-0037
Page 68 of 70
RAST2.5 Semi-Automatic Terminator Machine
Connector
Circuit Size
Series No.
2
91717-0038
91717-1001
3
91717-1009
4
91717-2001
5
91717-3001
6
91717-4001
91717
7
91717-5001
8
91717-6001
9
91717-7001
10
91717-8001
3
92332-0043
92332
5
92332-0045
8
92332-2048
92336-0001
3
92336-0018
92336-0041
92336-0501
4
92336-0530
92336-0544
92336-1001
5
92336-1008
92336-1015
92336-1501
92336-1508
92336-1515
6
92336-1522
92336-1529
92336-1537
92336-2001
92336
7
92336-2009
92336-2016
92336-2501
8
92336-2508
92336-3001
9
92336-3008
10
92336-3501
11
92336-4001
12
92336-4501
13
92336-5001
14
92336-5501
15
92336-6001
16
92336-6501
17
92336-7001
18
92336-7501
19
92336-8001
20
92336-8501
93037-0001
3
93037-0252
93037-0259
93037
93037-0501
4
93037-0755
5
93037-1001
93037-1501
6
93037-1508
Doc: No: ATS-623006200
Revision: B
Connector Assembly Order No.
91717-0039
91717-1002
91717-1010
91717-2002
91717-3002
91717-4002
91717-0040 91717-0351
91717-1003 91717-1004 91717-1005 91717-1007 91717-1008
91717-1011
91717-2003 91717-2004 91717-2005 91717-2006
92332-2148
92336-0002
92336-0019
92336-0042
92336-0502
92336-0538
92336-0545
92336-1002
92336-1009
92336-0013
92336-0020
92336-0043
92336-0503
92336-0539
92336-0546
92336-1003
92336-1010
92336-0014
92336-0021
92336-0044
92336-0504
92336-0540
92336-0677
92336-1004
92336-1011
92336-0015
92336-0022
92336-0045
92336-0505
92336-0541
92336-0678
92336-1005
92336-1012
92336-0016
92336-0023
92336-0046
92336-0506
92336-0542
92336-0679
92336-1006
92336-1013
92336-0017
92336-0024
92336-1502
92336-1509
92336-1516
92336-1523
92336-1530
92336-1503
92336-1510
92336-1517
92336-1524
92336-1531
92336-1504
92336-1511
92336-1518
92336-1525
92336-1532
92336-1505
92336-1512
92336-1519
92336-1526
92336-1534
92336-1506
92336-1513
92336-1520
92336-1527
92336-1535
92336-1507
92336-1514
92336-1521
92336-1528
92336-1536
92336-2002
92336-2010
92336-2017
92336-2502
92336-2509
92336-3002
92336-3009
92336-3502
92336-2004
92336-2011
92336-2018
92336-2503
92336-2510
92336-3003
92336-2005
92336-2012
92336-2019
92336-2504
92336-2511
92336-3004
92336-2006 92336-2007 92336-2008
92336-2013 92336-2014 92336-2015
92336-0507
92336-0543
92336-1007
92336-1014
92336-2505 92336-2506 92336-2507
92336-2512 92336-2513 92336-2514
92336-3005 92336-3006 92336-3007
92336-3503 92336-3504
92336-4502 92336-4503 92336-4504 92336-4505
92336-5002 92336-5003
92336-6002
93037-0003
93037-0253
93037-0260
93037-0502
93037-0756
93037-1002
93037-1502
93037-1509
93037-0004
93037-0254
93037-0261
93037-0503
93037-0757
93037-1003
93037-1503
93037-1751
Release Date: 04-23-09
Revision Date: 06-18-09
93037-0005
93037-0255
93037-0262
93037-0751
93037-0758
93037-1251
93037-1504
93037-0006
93037-0256
93037-0301
93037-0752
93037-0759
93037-1252
93037-1505
93037-0007
93037-0257
93037-0302
93037-0753
93037-0251
93037-0258
93037-0303
93037-0754
93037-1253
93037-1506 93037-1507
UNCONTROLLED COPY
Page 69 of 70
RAST2.5 Semi-Automatic Terminator Machine
Connector
Circuit Size
Series No.
7
8
9
10
93037
11
12
13
2
93039
3
4
5
6
7
3
4
93050
5
6
7
8
9
10
11
12
13
2
93051
3
4
5
6
7
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Connector Assembly Order No.
93037-2001
93037-2501
93037-3001
93037-3501
93037-4001
93037-4501
93037-5001
93039-0001
93039-0254
93039-1001
93039-2001
93039-3001
93039-4001
93039-5001
93050-0001
93050-0012
93050-0020
93050-0501
93050-0508
93050-1001
93050-1501
93050-2001
93050-2501
93050-3001
93050-3501
93050-4001
93050-4501
93050-5001
93051-0001
93051-0008
93051-0019
93051-0028
93051-1001
93051-1008
93051-2001
93051-3001
93051-4001
93051-5001
93037-2002 93037-2003 93037-2004 93037-2005
93037-2502 93037-2751 93037-2752
93037-3002 93037-3003
93037-3502
93037-4251
93037-5002 93037-5003 93037-5004 93037-5251
93039-0002 93039-0003 93039-0004 93039-0251 93039-0252 93039-0253
93039-0255 93039-0256
93039-2002
93050-0003
93050-0013
93050-0021
93050-0502
93050-0509
93050-1002
93050-1502
93050-2002
93050-2502
93050-3002
93050-3502
93050-4002
93050-0005 93050-0006 93050-0007 93050-0008 93050-0009
93050-0014 93050-0016 93050-0017 93050-0018 93050-0019
93051-0002
93051-0012
93051-0020
93051-0029
93051-1002
93051-0003 93051-0004 93051-0005 93051-0006 93051-0007
93051-0013 93051-0014 93051-0015 93051-0017 93051-0018
93051-0021 93051-0024 93051-0025 93051-0026 93051-0027
93050-0503 93050-0504 93050-0505 93050-0506 93050-0507
93050-1003 93050-1004 93050-1005
93050-1503 93050-1504 93050-1505
93050-2003
93050-2503
93050-3503
93051-1003 93051-1004 93051-1005 93051-1006 93051-1007
93051-2002 93051-2003 93051-2004 93051-2005 93051-2006
93051-3002
93051-4002 93051-4003 93051-4004
93051-5002
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc: No: ATS-623006200
Revision: B
Release Date: 04-23-09
Revision Date: 06-18-09
UNCONTROLLED COPY
Page 70 of 70
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