molex RAST 5.0 Manuale utente
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 1 of 65
Revision: A Revision Date: 04-2 -09
RAST 5.0 SEMI-AUTOMATIC TERMINATOR MACHINE
For Appli-Mate™ Co ectors (12 a d 16 AMP)
Order No. 62300-6100
I structio Ma ual
Description
Operation
Maintenance
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 2 of 65
Revision: A Revision Date: 04-2 -09
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, Co tact Your
Local Molex Sales Office
Molex Applicatio Tooli g Group
2200 Welli gto Court
Lisle, Illi ois 60532
Tel: 630-969-4550
Fax: 630-505-0049
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 3 of 65
Revision: A Revision Date: 04-2 -09
Table of Co te ts
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
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 4 of 65
Revision: A Revision Date: 04-2 -09
Sectio 1
Ge eral Descriptio
1.1. Description
1.2. Technical Specifications
1.3. Applicable Products and Wires
1.4. Delivery Check
1.5. Cє Certificate
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 5 of 65
Revision: A Revision Date: 04-2 -09
1.1 Descriptio
The 62300-6100 APPLI-MATE™ (RAST 5.0)
Semi-Automatic Terminator Machine, is designed
to terminate the APPLI-MATE™ (RAST 5.0)
female connector series (90 35, 91779, and
92000) onto discrete wire (1.0-1.5 mm2 and 16-1
AWG). This machine will accommodate circuit size
2 through 4.
1.2 Tech ical Specificatio s
Power Specificatio s:
To function correctly, these fixtures require the
following services:
Electrical Service
115/220 VAC 50/60 HZ 1 Phase 2 AMPS
P eumatic Service
6 BAR ( 5 psi) Minimum Clean, Dry and Filtered
Air Source
Pressure Gauge Setti gs
Main supply to machine - 6 BAR ( 5 psi)
1.3 Applicable Products A d Wires
Co ectors
Appli-Mate™ RAST 5.0 connector series 90 35,
91779, and 92000. See Connector Chart in
Section 6.
Wires
Conductor: 1.5mm², 1.0mm², 16AWG, and
1 AWG
Insulation outer diameter: 3.5mm maximum.
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.
62300-6100 Semi-Automatic Terminator
Machine for APPLI-MATE™
(RAST 5.0)
ATS-623006100 Instruction Manual
1.5 CE Complia ce
Complies with the ge eral health a d safety
requireme ts i accorda ce with:
-Council Directive 9 /37/EEC
-Council Directive 9/336/EEC and amended by 92/31/EEC
-Council Directive 73/23/EEC
This machi ery has bee desig ed a d
ma ufactured i accorda ce with the
followi g tra sposed harmo ised Europea
sta dards.
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 limits.
EN349: 1993, Safety of Machinery-Minimum gaps to avoid
crushing of parts of the human body.
EN41 : 1992, Safety of Machinery-Emergency stop
equipment, functional aspects- Principal for design.
EN60204 part 1: 1993, Safety of Machinery-Electrical
equipement of machines-Specification for general
requirements.
RAST 5.0 Semi-Automatic Terminator Machine
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Revision: A Revision Date: 04-2 -09
Sectio 2
Start-Up / Shut Dow Procedures
2.1. General Operation
2.2 Machine Operation and Process Flow
2.3 Operator Set Up And Functions
RAST 5.0 Semi-Automatic Terminator Machine
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Revision: A Revision Date: 04-2 -09
2.1 Ge eral Operatio
2.1.1 Prelimi ary
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 (Whe above co ditio s are met)
1. Reset the power by pushing the Reset button.
2. Wait approximately 5 seconds for the air supply to reach operating pressure.
3. Home the sensor motor. See section 4.1 (screen 5).
4. Enter the circuit size. See section 4.1.
5. Press Start button.
2.1.3 Start-Up Followi g A Fault
1. Identify the fault on the touch screen.
2. Correct fault.
3. Reset the power by pushing the Reset button.
4. Wait approximately 5 seconds for the air supply to reach operating pressure.
5. Home the sensor motor.
6. Press Start button.
2.14 Start-Up After A Emerge cy Stop Or Guard I terrupt
1. Release Emergency Stops or close guard doors.
2. Press Reset button on operator panel.
3. Wait approximately 5 seconds for the air supply to reach operating pressure.
4. Home the sensor motor.
5. Press Start button on operator panel
2.1.5 Start-Up After A Power Failure
1. Release Emergency Stops or close guard doors.
2. Press Reset button on operator panel.
3. Wait approximately 5 seconds for the air supply to reach operating pressure.
4. Home the sensor motor.
5. Enter the Circuit size.
6. Press Start button on operator panel
2.1.6 System Shut Dow
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.
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page of 65
Revision: A Revision Date: 04-2 -09
2.2 Semi-Automatic Termi ator Machi e Operatio a d Process Flow
2.2.1 Co ector I feed
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.
RAST 5.0 Semi-Automatic Terminator Machine
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Revision: A Revision Date: 04-2 -09
2.2.2 Co ector Separate (Cut Loose)
1. In the automatic mode the connectors are transferred to the cut station by the connector feed.
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 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 Clamp
A
Clamping Cylinder
B Knurled Screw to tighten/release
the adjustable gripper jaw
C Rail Clamp Screw
RAST 5.0 Semi-Automatic Terminator Machine
Doc: No: ATS-623006100 Release Date: 04-2 -09 UNCONTROLLED COPY Page 10 of 65
Revision: A Revision Date: 04-2 -09
2.2.3 Co ector Tra sfer
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 Transfer Cylinder
B Connecting Rod
C Transfer Rod
D Out Feed Pawl
2.2.4 Wire Feed (Mask Tooli g)
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 by engaging spring-loaded comb tooling from below.
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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