Tyco Electronics RAYCHEM WAFFLE IRON II Istruzioni operative
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 1 of 16
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RAYCHEM
INTERCONNECTION SYSTEMS DIVISION
ENGINEERING STANDARD
ES 61402
OPERATING AND MAINTENANCE MANUAL
WAFFLE IRON II HEATING TOOL
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 2 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
OPERATING AND MAINTENANCE MANUAL
WAFFLE IRON II HEATING TOOL
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 3 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
WARNING The Waffle Iron II has exposed hot surfaces.
WARNING To prevent danger of electric shock, do not remove covers. There are no user-serviceable
parts inside.
WARNING When using release agent in pressurized containers, read and observe all manufacturer's
precautions, warnings, and instructions.
WARNING Do not touch infrared lamps. They may be hot and can cause burns.
WARNING In keeping with good industrial hygienic practice, adequate ventilation must be
maintained whenever plastic materials are heated.
CONTENTS
SECTION SUBJECT
1. Description
1.1 General
1.2 Function
1.3 Specifications
2. Preparation For Use
2.1 Power connection
2.2 Platen installation
3. Operating Instructions
3.1 Turn-on procedure
3.2 Control settings
3.3 Termination procedure
4. Calibration Verification Test
4.1 Objective
4.2 Tools required
4.3 Procedure
5. Maintenance
5.1 Cleaning
5.2 Preventing parts from
sticking
5.3 Upper heat sink hinge
adjustment
5.4 Troubleshooting
5.5 Replacement parts list
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 4 of 16
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1. Description
1.1 General
Raychem's Waffle Iron II is a portable heating tool for terminating components of Raychem's
Integrated Interconnection System (I2S). The Waffle Iron II contains a microprocessor-based
controller which provides heating time and temperature adjustment, fault and error
monitoring, and display of operational status.
Standard product applications include: CTM splice modules for flat conductor cable, CTM
transitions for splicing flat conductor cable to round wire, MTC50 and MTC100 connector
wafers for flat conductor cable, and SEM connector wafers for flat conductor cable.
The part to be terminated is fixtured between two platens which hold the part in place and
apply heat and pressure during the termination cycle.
Each platen is heated by an infrared quartz lamp. To accommodate different interconnection
components, different platens are used, which snap in and out of their mounting fixtures. The
upper platen and lamp are mounted in a hinged heat sink which opens for loading and
unloading.
Controls include a power switch, a heating time control, a temperature control, and a button
to initiate the heating cycle. Four indicator lights provide the operator with operational status
information.
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 5 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
1.2 Function
When the Waffle Iron II power is switched on, the controller undergoes a self test. If the
circuits are functioning properly the green READY/ERROR light will illuminate, and the
unit is ready for use. A heating cycle is initiated by pressing the START button, which turns
on the infrared lamps and the HEATING indicator light.
When the platens reach the set-point temperature, the timer starts and the controller regulates
the platen temperature for the time period selected. After the timed heating period the heat
lamps and HEATING indicator light go out, the COOLING indicator light illuminates, and
the blower comes on to cool the platens. The cooling cycle lasts 3 minutes or until the platens
cool to 125°F, whichever occurs first. At the end of the cooling period the green
READY/ERROR indicator light illuminates, and the terminated component can be removed.
The green READY/ERROR indicator light will flash continuously if the operator makes one
of the following errors:
oAttempting to start a heating cycle without first opening the upper heat sink to
remove completed termination.
oFailing to close upper heat sink before starting a cycle.
oOpening upper heat sink during heating cycle.
Flashing red FAULT light indicates a hardware failure requiring repair by a Raychem field
service representative.
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 6 of 16
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1.3 Specifications
Power Requirements Model CE-1404200 (120 V) 100-120 VAC,
50-60 Hz, 20 A
Model CE-1404300 (240 V) 200-240 VAC,
50-60 Hz, 10 A
Overall Cycle Time 3-4 Minutes
Temperature Per TEMP control dial: Setting "0" through "9"
Set-Point Range
Time at Temperature Per TIME control dial: Setting "0" through "9"
Setting Range
Product Capacity CTM splices for flat conductor cable
CTM transitions for flat cable to round wire
MTC50 and MTC100 connector wafers for flat conductor cable
SEM connector wafers
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 7 of 16
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2. Preparation For Use
2.1 Power Connection
Connect the Waffle Iron II to a grounded 50 or 60 Hz power source of the current capability
and voltage specified on the back of the heating tool.
2.2 Platen Installation
Step 1
Select the correct platen set as called out in the product installation instructions.
Step 2
Before installation or after cleaning, spray or wipe platens with light coat of release agent,
such as Miller-Stephenson MS-122* or Axel MoldWiz**.
oCoat only the side of the platen that comes into contact with the part being
terminated.
Step 3
Make sure that the power is turned off.
Step 4
Unlatch and open the upper heat sink by pushing it down and releasing it.
*Miller-Stephenson Chemical Co., Inc.
Danbury, Connecticut 06810
** Axel Plastics Research Laboratories, Inc.
41-14 27th. St., Long Island City, NY 11101
WARNING
When using release agent in pressurized containers,
Read and observe all manufacturer’s precautions, warnings,
and instructions
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 8 of 16
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Step 5
Remove/install platens as required.
oPlatens are locked into heat sinks by a spring-loaded retainer.
oIdentification markings face the operator.
oTop platen has one keying slot.
oBottom platen has two keying slots.
WARNING
Do NOT touch infrared lamps. They may still be
hot and can cause burns.
Step 6
Close and latch the upper heat sink.
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 9 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
3. Operating Instructions
3.1 Turn-On Procedure
Step I
Make sure that set-up is completed as detailed in section 2.
Step 2
Turn on the power (ON-OFF) switch.
oThe green READY/ERROR light will illuminate steadily when the self test is
completed and the tool is ready for operation.
oIf the green READY/ERROR light is flashing, the upper heat sink is probably not
closed and latched.
oIf the red FAULT light is flashing, a hardware failure is indicated. Turn the unit off
and contact a Raychem field service representative.
Step 3
Press the START button to initiate a heating cycle to warm the tool and verify its operation.
oThe TEMP and TIME controls can be at any setting for this cycle.
oThe green READY/ERROR light should go out and the yellow HEATING light
should illuminate. Light from the heat lamps should be visible under the upper heat
sink, and the heat sink should become warm.
oWithin one minute the yellow HEATING light should go out and
the yellow COOLING light should illuminate. The light from
the heat lamps should go out and the cooling
fan should come on.
oWithin three minutes the yellow COOLING light should go out
and the green READY/ERROR light should illuminate.
The fan should go off at this time.
3.2 Control Settings
Set the TEMP and TIME controls as specified for the particular component being terminated.
oRefer to the appropriate product installation instructions for control settings.
Wire and Harnessing Products
Engineering Specification
No: ES 61402
Rev: D
Date: July 9, 1991
Page: 10 of 16
If this document is printed it becomes uncontrolled. Check for the latest revision.
3.3 Termination Procedure
WARNING
In keeping with good industrial hygienic practice, adequate ventilation must be
maintained whenever plastic materials are heated.
Step 1
Make sure that the set-up is completed (section 2), the tool is turned on and warmed up (para. 3.1),
and the TEMP and TIME controls are set (para. 3.2).
Step 2
Open the upper heat sink and the cable clamps.
Step 3
Load the assembly to be terminated onto the lower platen of the heating tool.
oPosition CTMs so that the top surface faces upward and the CTM is centered in the
platen.
oPosition MTC and SEM connector wafers against the stop in the platen, with the
contact numbers facing upward. The cable or wires should extend to the operator's
right.
oPosition round wires through the platen comb and close the clamp.
Step 4
Line up the edges of the cable (FCC) with the cable guide lines in the top surface of the heating
tool, and close the clamp(s) on the cable.
Step 5
Inspect to make sure that the cable or wires are fully inserted and properly positioned on top of the
solder terminals. Reposition cable or wires if necessary.
Step 6
Close and latch the upper heat sink.
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