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Contents
I. Precautions ............................................................................................. 1
II. Specification .......................................................................................... 1
III. Operation Methods ............................................................................. 1
3-1. Precautions during installation of machinery ...................................................................... 1
3-2. Description of parts ............................................................................................................. 2
3-3. Preparation for operation ..................................................................................................... 3
3-4. Operation of HMI setting .................................................................................................... 3
1-[Origin Windows] ............................................................................................................ 3
2-[Operation Windows] ...................................................................................................... 4
3-[Setting Windows]. .......................................................................................................... 8
4-[Count & Speed Setting] ................................................................................................. 9
5-[Manual Windows] ........................................................................................................ 10
6-[Detection & Auxiliary Windows] ................................................................................ 12
7-[Time Parameter Setting]............................................................................................... 15
8-[Modify Position] .......................................................................................................... 17
9-[Cutter set parameters] .................................................................................................. 19
10-[User Level Entry] ....................................................................................................... 21
11-[Button Functions] ....................................................................................................... 21
12-[Alarm Windows] ........................................................................................................ 22
IV. Change and maintenance of blades ................................................. 24
4-1. Change of blades ............................................................................................................... 24
4-2. Maintenance ...................................................................................................................... 25
V. Failures and solutions ......................................................................... 25
5-1. Table of failures and solutions ........................................................................................... 25
5-2. Table of errors and troubleshooting methods .................................................................... 26
VI. Additional descriptive items ............................................................ 28
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I. Precautions
※ Forbid the table top from being cleaned with high-pressure air rifle,in case a cut of
wire jacket dropping into the mechanism impacts normal operation.
The power supply section must be grounded.
II. Specification
Warranty period: one year (i.e., 2,500 hours, excluding consumptive parts)
Model
BZW-2.0X
Capacity
wire length 50mm,about 3,600wires/hour(single-terminal crimping )
Applicable wire
AWG # 32 ~ AWG#18
diameter
Processing length
(Central section with jacket remaining)21mm~99,990mm (shorter for refitting)
Stripping length
Front0.1~8.0mm
Cutter depth
Maximum adjustment 3.50mm
Cutting tolerance
Modifiable
crimping capacity
2 Tons
Detection device
Low air pressure, existing of electric wire, abnormal stripping, abnormal crimping,
rear0.1~10.0mm
resolution 0.01mm
abnormal ingoing wire, etc.
Auxiliary device
Prewire feeding synchronizer, terminal waste paper rewinding device
power supply
single phase, AC180V~242V, 50/60Hz, 10A
Compressed air
0.5 MPa(5kgf / cm2) clean dry air
Dimension
1,800W × 900D × 1,450H, about 460KG
III. Operation Methods
3-1. Precautions during installation of machinery
A. Precautions during machinery set-up on the floor
Put 4 holding foot stocks under the machine. Adjust the height to secure the levelness.
B. Air connections
Connect the air from air compressor to the quick connector of this machine, and adjust with
filter regulator the pressure to 5kgf / cm2.
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Change the filter screen of filter regulator once every two months, so as to maintain the best
operation performance of machine.
C. Wiring of power supply
Connect the power wire to (AC220V single phase, 50/60Hz, the voltage is different in different
parts) power connector, which must be grounded.
3-2. Description of parts
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A01 stacker
A02front press A03 terminal feeding guide plate
A04 touch HMI
A05 run button
A06power switch
A07 Main switch for over-current protection;
A10Take-up block
A08machine holding foot stock;A09rear press
A11 take-up reel A12air pressure adjustment valve
manual switch of compressed air
A14 filter
A13
A15waste collecting vessel
3-3. Preparation for operation
A. Switch on the power supply, which must be grounded.
※[The power supply must be single phase, AC180V~242V, 50/60Hz, 10A, otherwise the
machine may be damaged.]
Press the power switch once (POWERON), and then various values show up on indication bars
of main operation board.
B. Switch on the air supply
Connect the compressed air supply to quick connector, and adjust the default pressure of A12
compressed air pressure regulator of this machine to (5kgf / cm2).
Please keep the air supply pressure above 5kgf / cm2. If it is lower than 3.5 kgf / cm2, the
machine cannot work normally and HMI (human-machine interface)will indicate [Air pressure
too low]. Before adjusting A12 compressed air pressure regulator, lift the knob first. Clockwise
= air pressure turns higher; counter-clockwise = air pressure turns lower.
3-4. Operation of HMI setting
※Forbid HMI from being touched by hard or sharp objects, otherwise the touch
panel will be damaged!!!!
1-[Origin Windows]:
Switch on the power supply, and about 30 seconds later HMI will display the initial screen.
Confirm there is no foreign matter in work area, and touch the display screen.
Touch Origin Startand the machine will restore to the origin automatically. This machine has
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operating languageoption
option at its left bottom for language selection.
※ As shown above, each shaft drive mechanism corresponds to two limit sensors
sensors. Ensure the
machine before restoring to origin is within the range of limit sensors, otherwise restoration may
fail.
2-[Operation
[Operation Windows]: After restoration to the origin, the machine shows main
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operation screen automatically.
a-Drawingof wire processing:
processing: Reflects various processing conditions currently set.
b-F-X Axis:: Represents the horizontal coordinate of feed roller drive shaft
shaft.
c-R-X Axis: Represents the horizontal coordinate of Sending Clamp drive shaft
shaft.
d-R-Y Axis: Represents the vertical coordinate ofSending Clamp drive shaft
shaft.
e-Cutter: Represents the coordinate of knife edgedrive.
f-Capacity:Represents the number of cycles during operation per hour.
g-Total:Displays the total number of processed currently set.
h-Complete:Displays
Displays the finished count currently. Under this setting, there are two keys
keys▲ ▼ for
modifying values.
i-Units Suspended:When
en the count of cutting process reach the preset value, display screen
prompts time suspension.
j-F-Press ON:Under
:Under stop or Decomposemotions
Decompose
mode, this function key at the bottom of main
operation screen can be operated to make front pressON
ONorOFF.(This switch can
only control stamping signals of terminal press instead of controlling power
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supply)
k-R-Press ON:Under stop or Decompose motionsmode, this function key at the bottom of main
operation screen can be operated to make rear press ONorOFF.(This switch can
only control stamping signals of terminal press instead of controlling power
supply)
l- D: Displays the wire core OD cutter depth currently set.
m-Y: Displays the tool retracting value of stripping currently set.
m-JogStopStart: These three lights respectively correspond to the machine operation state at that
time.
Front Stripping Detection
Rear Stripping Detection
n-stripping detection (front & rear):These two lights respectively reflect the results of front
stripping detection and rear stripping detection. If detection result is normal, lights is ON. For
front stripping detection andfront terminal detection,functions are detected with the same fiber
detection device by blocking the optical fiber source of mutual illumination. In the case of
stripping detection (front & rear), adjust the wire forward/backward movement according
tosettings of Position Correction Setup Windowand Stripping Detection Position, to ensure
that copper wires can block the optical fiber source of mutual illumination and complete
detection operation. If too many copper wires are broken, they can not block light rays and it is
judged to be abnormal stripping. In Detection & Auxiliary Windowsthere are respectively
front & rearstripping detectionfunction On-Off keys. If such a key is ON, the machine will
stop automatically and give alarm notification when abnormal strippingis detected out; if it is
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OFF, it is impossible to judge abnormal stripping.
Rear Crimping Terminal Detection
O-terminal detection (front & rear): These two lights respectively reflect the results of front
crimping terminal detectionand rear crimping terminal detection. If detection result is normal,
lights is ON. For front stripping detection andfront terminal detection,functions are detected
with the same fiber detection device by blocking the optical fiber source of mutual
illumination. In the case of front terminal detection, adjust the wire forward/backward
movement according to settings of Front Terminal Detection Positionof Position Correction
Setup Windows,to ensure that the terminal can block the optical fiber source of mutual
illumination and finish detection operation. If the upper terminal is not crimped, the fiber
could not be blocked and it is judged as abnormal front crimping. The rear crimping terminal
detection device is below retriever, as shown in the figure above. While returning to take-up
reel,the processed wires held by wire clipwill pass by optical fibers of rear crimping terminal
detection, and such optical fibersare of co-axial reflection type. The principle of rear crimping
terminal detection is that co-axialoptical fibers are reflected by the rear crimping terminal.
In Detection & Auxiliary Windows,there are respectively (front & rear)crimping Detection
function On-Off keys. If such a key is ON, the machine will stop automatically and give alarm
notification when abnormal stripping is detected out.
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3-[Setting Windows]: Setting of processing conditions.
a-[Machining Mode]: setting range 0 ~ 2.
Mode 0 >> Front/Rear Crimped Terminal Operation Mode selection: When the operation mode is
changed, the drawing below will changes accordingly. The setting of such modeas
Rear Half Strip (B)is invalid, because complete strip is mandatory.
Mode 1 >> F-terminals detection Err: The rear terminal is half stripped, and the half stripping
length is controlled by Rear Half Strip (B).
Mode 2 >> Rear Crimped Terminal: The front terminal is completely stripped. This is mandatory
because front terminal is fixed.
b-[Front Strip Len. (F)]: Set the Front Strip Length.
c-[Rear Strip Len. (R)]: Set theRear Strip Length. After the setting is changed, press the start key
and the machine will automatically restores to origin.
d-[Rear Half Strip (B)]: Set the rear length of stripped wire jacket. It is valid in mode 1 only.
e-[Total Length (L)]: Set the Total Length of processed wire.
f-[wire core OD D]: Set the Depth of Cutter Feeding during stripping.
h-[Blade Way Back (Y)]: Set theOpening of Retracting during stripping. In the case of stripping,
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feed the cutter (D) first; retract the cutter (Y) after it cuts the wire jacket, to separate the blade from;
last, pull the wire jacket. Avoid the blade from scratching the wire core.
※ If the opening of retracting is too small, it may cause the blade scratchesthe wire core.
i-[Modify Wire Length]: The actual length may differ from that determined by roller by a scale
tolerance due to differences in wire material and hardness. Such scale can be set inModify Wire
Length, and it can be modified to meet the actual length.
Setting range 95.0 % ~ 105.0 % The higher the value is, the wire after modification will be
longer.
j-[File No.]: Display the setting data File No.of target wire processing.
k-[Open files]: Setting data of wire processing may be saved in 30 groups (0 ~ 29) in total;
This function may open the saved setting data of wire processing.
l-[Save as..]: Setting data of wire processing may be saved in 30 groups (0 ~ 29) in total;
This function may save the present setting data of wire processing under
a designated file number.
4-[Count & Speed Setting]: Set the count and speed conditions.
a-[Total finished]: Modify and set the quantity of wires now processed.
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b-[Total quantity]: Set the preset total quantity of wires to be processed. WhenTotal finished>=
Total quantity, the machine stops automatically.
HMI displays the quantity of wires processed.
c-[Per bundle]: Set the quantity in each small batch.
d-[Number of pause]: Set the time of pause in second(s) after each bundle is finished. When it is
up, the machine starts automatically.
If the setting is 0, the machine does not start automatically.
e-[Feeding Speed]: Set thefeed roller speedwithin 0 ~ 9. The higher the value is, the higher the
speed is.
f-[X Axis speed]: Set thehorizontal movement speed of front and rear drive shafts,within 0 ~ 9.
The higher the value is, the higher the speed is.
g-[Cutter Speed]: Set the speed of cutter movement within 0 ~ 9. The higher the value is, the
higher the speed is.
h-[Y Axis Speed]: Set the vertical movement speed of rear Sending Clamp within 0 ~ 9. The
higher the value is, the higher the speed is.
j-[Pre-Feed Spd]: Set the pre-feed roller speed within 0 ~ 9. The higher the value is, the higher the
speed is. Pre-feedmay bear a heavy load. The higher the motor speed is, the smaller the force is.
Generally, pre-feed roller speedmay be set to a low value, and this machine will detect it
automatically. If the setting of pre-feed roller speedis too low to ensure the wire feeding offeed
roller, alarm is given automatically.
5-[Manual Windows]: test motions of individual air cylinders and valves.
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a-[Pressure
conditions,
Wire]:
Under
normal
Wire Clips stays
in the
following state(without Pressure Wire).
pressure wire height limit
PressPressure Wireto shift to Lift Pressure
spring conduit
Wire. Each press changes Wire Clips state
in cycle. During front stripping, such Wire
Clipspress the wire, to avoid slipping.
pressure wire
conduit
There is a wire pressing cylinder at the
bottom of figure, and its wire-pressing
tube holds wires during stripping. As shown in the figure, there are M4 screws and they can be
loosened clockwise to open the Wire Clips. Thus, M4 screws can adjust the height of Pressure Wire,
to prevent damages to wire.
b-[Front Stripping]: Press Front Strippingonce to change Front Strippingforward or backward in
cycle.
c-[Knife Blow]: PressKnife Blowonce to changeON/OFF state of knife blowsolenoid valve。
d-[Sending Clamp]: Under normal conditions, Sending Clamp stays in the state of opening and
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sinking. PressSending Clampto switch into lifting and closed state. Press Sending Clamponce to
change Sending Clamp state in cycle.
e-[Lift Wire]: Under normal conditions, wire pallet is retracted. Press Lift Wireto switch
tolaunched. PressLift Wireonce to changethe wire pallet state in cycle.
f-[Retrieving Clamp]: Press wire clip once to changethewire clipsolenoid valveON/OFF state in
cycle.
g-[Retrieving Clamp Movement]: Press Retrieving Clamp Movement once to change
theRetrieving Clamp Movementsolenoid valveON/OFF state in cycle.
h-[Cutting Tab]: Press Cutting Tabonce to changetheCutting Tabsolenoid valveON/OFF state in
cycle.
i-[Fr. Feeding]:Press Fr. Feeding, and the feed roller&pre-feed will move forward slowly. Release
the key to stop.
j-[Rev Feeding]:Press Rev Feeding, andthefeed roller will movebackward slowly . Release the key
to stop.
6-[Detection & Auxiliary Windows]: Validity of detection function and reaction of
sensor.
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a-[Stripping detection]: Conductstripping detection at front and rear terminals respectively.
Stripping detection is to detect whether the wire core is cut off. Set ON or OFF on corresponding
button. ON means detection function starts. If an abnormality is detected out, the function will
stop automatically and indicate abnormal X-axis stripping.
※stripping detectionmust works with [XStripping Detection Position] ofModify Position, to
ensure wire core passing by sensor can block light rays. It is judged whether the wire core is cut
off in such way.
b-[Crimping detection]: Conduct crimping detectionat front and rear terminals respectively.This
function is to detect whether terminals are crimped. Set ON or OFF on corresponding button. ON
means detection function starts. If an abnormality is detected out, the function will stop
automatically and indicate abnormal X-axis crimping.
※Terminal crimping detectionmust works with the setting of [Xterminal detectionposition] of
Modify Position. When wires pass by the sensor, light rays are blocked by terminal. By this way,
judge whether front crimping is abnormal.
c-[Wire Detection]: Conduct Wire Detection on wires passing by Wire Collector. Set ON or OFF
on corresponding button. ON means detection function starts. If ingoing wire pulling or using up
is detected out, the function will stop automatically and indicate ingoing abnormality.
d-[Detection of auxiliary display]: 16 circle lights on the screen indicate the state of
corresponding machine functions. If the light is on, the function it corresponds is ON.
1-F-Press: This optical fibers sensor is used for detecting the front stripping and cutting and front
pressed terminal.Judge whether objects pass according to the intensity of mutual illumination. If
light rays are blocked, the light is ON.
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wire block
cam opening
stripping and pressing
pressure adjustment
feeding roller
wire collector
tenseness
stripping sliding
absence of wires
table
pulling of wires
rear limit of
(Fig. 1)
stripping
(
(Fig. 2)
2-Wire Abnormal: This light is ON either when the wire puller at the entry of Wire Collectoror in
the case of wire use-up or absence.
3-Pre-Feed: Detect the tenseness of fed wire at the exit ofWire Collector, and lift means ON.This
sensor is on even when [Wire Detection] is off. But, it means there is wire pulling if the light is still
on after pre-feed is finished. In this case, the machine will stops automatically and indicate
abnormal Pre-Feed.
4-Finishing Wire: Left limit sensor ofRetrieverTake-up block clamp.
5-Cutter_H:Cutter_H sensor.
6-Strip R_S: rear limit sensor of front stripping block, as shown in Fig. 2 above
7-Pressure: Detect the compressed air pressure.When air supply pressure is lower than 3.2 kgf /
cm2, the machine cannot work normally and HMI (human-machine interface)will indicate [Air
pressure too low].
8-F-X AxisH: F-X Axis origin sensor.
9-R-X AxisH: R-X Axis origin sensor.
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10-R-Y AxisH: R-Y Axisorigin sensor.
11-R-Press: Detect the rear crimping terminal, and optical fibersare of co-axial reflection type. The
principle of rear crimping terminal detection is that co-axialoptical fibers are reflected by the rear
crimping terminal.
In Detection & Auxiliary Windowsthere are
respectively
front
and
rear
Crimping
detectionfunction On-Off keys. If the key is set to
ON, a detected R-press abnormality will lead to
machine stop and alarm notification.
12-F-X-ALM:-F-X-ALM drives the alarm signals
input.
13-R-X-ALM:-R-X-ALM drives the alarm signals input.
14-R-S-Test: rear stripping detection signals input as
shown right.
15-F-X AxisL: Input the protective sensor signals of
stroke limit
16-R-X AxisL: Input the protective sensor signals of stoke
limits
7-[Time Parameter Setting]: Time parameters of machine movement.
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a-[Rear crimping stop time]: Only if the rear crimping stop time set for rear terminal crimping is
up, drive mechanism will start the next motion.
b-[Front crimping stop time]: Only if the rear crimping stop time set for front terminal crimping
is up, front drive mechanism will return to Cutter_Hposition.
c-[Clipping period]: Cutter_H operation. Ensure the electric wire is stably held by Sending
Clamp before cutting offelectric wire. This setting can delay the clipping period, to ensure the
electric wire is stably held by Sending Clamp. Then, cut off the electric wire.
d-[Retrieving Clamp Delay]: Adjust the delay of wire clip holding wires through this setting.
e-[Cutting TabCycle]: Set the cycle of continuous waste band cutting. If the value is set to 10,
then the terminal cut off continuous waste bands once every 10 times of crimping. If it is set to 0,
cuttingtab can be skipped.
f-[Lift Wire]: Supporting plate shown below is used to finish front terminal crimping. In order to
prevent wire head from drooping, the head of outgoing wires can be held by supporting plate.
If the setting is “0”, this function is Off; if the setting is “1”, the function is On.
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8-[Modify Position]: Modify the position of drive mechanism stop.
Red arrows indicate the direction towards which a high value is modified.
a-[Rear Stripping Detection Position]: After the rear stripping is set, adjust the wire forward
or backward movement to ensure copper wires may block the optical fiber source of mutual
illumination and complete detection operation. If too many copper wires are broken, they can
not block light rays and it is judged to be rear stripping abnormity.In Detection & Auxiliary
Windowsthere is a stripping detectionfunction On-Off key. If such a key is ON, the machine
will stop automatically and give alarm notification when abnormal stripping is detected out.
b-[Front Stripping Detection Position]: After the front stripping is set, adjust the wire forward
or backward to ensure copper wires may block the optical fiber source of mutual illumination
and complete detection operation. If too many copper wires are broken, they can not block
light rays and it is judged to be front stripping abnormity.In Detection & Auxiliary
Windowsthere is a stripping detectionfunction On-Off key. If such a key is ON, the machine
will stop automatically and give alarm notification when abnormal stripping is detected out.
c-[X-axis position of the rear crimping]: Set the horizontal (left or right)positionmodification
of wire conduit and target terminal during adjustment of rear crimping terminal.
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d-[X-axis position of the front crimping]: Set the horizontal (left or right)position
modification of wire conduit and target terminal during adjustment of front pressed terminal.
e-[Y-axis position of the rear crimping]: Set the vertical (front or rear) position modification
of wire conduit and target terminal during adjustment of rear crimping terminal.
e-[Y-axis position of the front crimping]: Set the vertical (front or rear) position modification
of wire conduit and target terminal during adjustment of front pressed terminal.
f-[Rear terminals detection pos. ]: Rear crimping terminals are detected with co-axial
reflectiveoptical fibers, according to the principle
that co-axialoptical fibers are reflected by the rear
crimping terminal. In Detection & Auxiliary
Windowsthere
are
respectively
front
and
rearstripping detectionfunction On-Off keys. If such
a key is ON, the machine will stop automatically
and give alarm notification when abnormal stripping
is detected out.
Adjust the Rear terminals detection pos. by the following ways:
1- Loosen slightly the co-axial optical fiber holder(-M4 screw) and then adjust the angle
of holder to the extent thatco-axial optical fiberscan shine the terminal. Then, finish
detection.
2- Modify the setting ofRear terminals detection pos.After that, press start key and the
machine will adjust the sending clamp position automatically. A higher value means the
clamp is closer to blade and that the crimped terminal is farer away from co-axial
optical fibers.
g-[Front terminals detection position]: Set the front pressed terminal first. Adjust wires
forward or backward, to ensure the front terminal can block the optical fiber source of mutual
illumination. Finishdetection. If the upper terminal is not pressed, the fiber could not be
blocked and it is judged as F-Press abnormity. In Detection & Auxiliary Windowsthere is a
Crimping detectionfunction On-Off key. If such a key is ON, the machine will stop
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automatically and give alarm notification when front crimping abnormity is detected out.
h-[Wire clip X-position]: Adjust the horizontal (left or right)position of wire connection
between R-X AxisSending Clampandwire clip .
9-[Cutter set parameters]: Test wire parameters to be set.
In the former [Setting Windows], there are two settings [wire core ODD] and [Stripping and
retracting Y].
a-[wire core ODD]: Set the Depth of Cutter Feeding during wire jacket stripping.
b-[Stripping and retracting Y]: Set the Opening of Retractingduring wire jacket stripping. In the
case of stripping, feed the cutter (D) first; retract the cutter (Y) after it cuts the wire jacket, to
separate the blade from; last, pull the wire jacket. Avoid the blade from scratching the wire core.
c-[Cutting Stroke Modify]: Set the stroke modification when a cutter can cut off electric wires.
This setting must ensure a long cutter can cut off electric wires, with a safety margin of
0.50mm~1.00mm.
Modification of this parameter requires entry of A1 password 1966.
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rear stripping knife
blade edge modify
blow air for throttle
front stripping knife
cutter
Since machine and blade processing has a tolerance, this machine is designed to have a cutter
depth correction cam. Close the stripping knife edge till a small gap, and watch with eyes if the gap
heights of front knife and rear knifeare the same. If it is required to adjust the height of knife edge,
loosen the fixing screws on front knife and the set screws at the right of cutter depth correction
cam. Rotate the cutter depth correction cam to a proper angle. Push the front knife upward and
toward the cam. Tighten screws.
d-[Fr. Feeding]: Keep this button pressed and feed roller will send electric wires at a certain speed.
Sending stops upon release of button.
e-[Rev Feeding]: Keep this button pressed and feed roller will retract electric wires at a certain
speed. Retracting stops upon release of button.
f-[Cutter origin]: Cutter_H returns to the origin.
j-[Cutting Test]: Test the position of Cutter_H cutting off electric wires. (total stroke of cutting)
-
k-[Stripping Test]: Test the position ofCutter_H. Finish (cutting stroke wire core OD ) before
(Stripping and retracting )。
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10-[User
[User Level Entry]: Technicians need passwords
passwords for entry if they want to change
special parameters.
Only operators with qualification are allowed to set
set some parameters with big influences.
A1 level: Select A1 and choose the correct entry password of A1 level. After the operation
interface displays technicians, change parameters.
A1 password xxxx forbids change of setting.
Items of A1 level.A1
11-[Button
[Button Functions]: Actual button functions.
a-[Jog]: 『Decompose
Decompose motions』
motions Press this button once and the machine will finish operations one
after another till one cycle is finished.
b-[Stop]: During automatic operation, the machine stops only after one cycle is finished.
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c-[Start]: The machine will operate continuously, till the set quantity is reached or till an abnormal
state is detected out.
d-[Emergency Stop]: Stop operation immediately. All servo motors will be released from locking
and HMI will indicate emergency stop.
This button is of closed and locked type. Once pressed, the button is locked at the pressed position.
It should be gently rotated clockwise for release from the state of Emergency Stop. The machine
should be reset to operate again.
12-[Alarm Windows]: Alarms of various abnormity.
During operation, this machine will detect abnormities automatically and gives alarms.
A. Emergency Stop: Receive signals of Emergency Stop.
B. Complete total: Count of processing>= Total quantity.
C. Unit stop: Count of processing>= Setting of Per bundle , and Number of pauseis set to 0.
D. Not at ORG: The present machine is not at the origin. It must return to the origin first.
E. F-X position Err: F-X Axis movement abnormity is detected out during operation.
F. R-X position Err: R-X Axis movement abnormity is detected out during operation.
G. F-strip base Err: An error of cylinder sensor signals of F-strip base abnormity is detected
out during operation.
H. F-stripping detection Err: Front Stripping abnormity of the front wires cut off is detected out
during operation.
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I.F-terminals detection Err: An abnormity of front crimping is detected out during operation.
J. Pre-Feeding Err: During machine operation, it is detected out that the wire feeding device
has finished movement. The feeding wire tenseness detector at the exit of whole wire
pre-feed stays in the ON state of lift. This sensor is on even when [Wire Detection] is off.
But, it means there is wire pulling if the light is still on after pre-feed is finished. In this
case, the machine will stop automatically and indicatePre-Feeding Err.
K.Infeed Err: InDetection Windowsonly Wire Detectionfunction in ON state is valid. During
operation of machine, wire pulling, or absence, or sensor signal error is detected out in
whole wire device.
L. R-Y position Err: R-Y Axis movement abnormity is detected out during operation.
M. Cutter_H Err: Cutter_H movement abnormity is detected out during operation.
N. R-stripping detection Err: Rear stripping abnormity of rear wire cut off is detected out
during operation.
O.R-terminals detection Err: An abnormity of rear crimping is detected out during operation.
P. Rear wire clip Err: A retrieverabnormity of cylinder sensor signal error is detected out
during operation of machine.
Q.Pre-feed slow: During operation of machine, it is automatically detected out that wire-feeding
device has finished movement but the pre-feed device has not, which may cause wire
pulling. Thus, the machine gives an alarm thatthe settings of Pre-Feed Speed is too low.
R.Air pressure too low: An abnormity of too low compressed airpressure is detected out. This
machine requires an air pressure of 5KG/CM in normal conditions. If air pressure is
detected out to be lower than 3.2KG/CM by more than 0.2 s during operation, the machine
gives an alarm. The right light of Air pressure too low captures the fact that air pressure is
lower than 3.5KG/CM by more than 0.2 s.
S. Length setting Err: It is detected out that Total Length< (Front Stripping length+ Front
Stripping length+ 8mm), and the machine gives an alarm ofLength setting Err.
T. F-Xsvo alarm: The operating machine gives an alarm for detected drive abnormity
ofF-X-ALM.
U. R-Xsvo alarm: The operating machine gives an alarm for detected drive abnormity
ofR-X-ALM.
V. F-X over limit: The operating machine gives an alarm for it is detected out that the front
X-axis drive mechanism moves beyond the limit.
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WR-X over limit: The operating machine gives an alarm for it is detected out that the rear
X-axis drive mechanism moves beyond the limit.
If the operating machine gives over-limit alarm, please check first whether there are foreign
matters in the limit sensorof corresponding mechanism. If yes, remove foreign matters and
restart the machine from the origin.
In the case of alarm for servo drive abnormity, the servo driver of electric control box
indicates error code. Switch off the machine for over 3 seconds, and then switch on again!!!
IV. Change and maintenance of blades
4-1. Change of blades
Cutter_H is equipped with 6 knifes (3 groups) in total: cutters in the middle; front stripping
knifes at the right, and rear stripping knifes at the left.When a blade is to be changed, cut off
the power supply first; fold the knife edge; change the blade, as shown below, with the
blade facing upward, ensure it is placed against the ejector pin; at last tighten screws.
rear stripping knife
blade edge modify
blow air for throttle
front stripping knife
cutter
This machine is designed to have cutter depth correction cam. Close the stripping knife
edge till a small gap, and watch with eyes if the gap heights of front knife and rear knifeare
the same. If it is required to adjust the height of knife edge, loosen the fixing screws on
front knife and the set screws at the right of cutter depth correction cam. Rotate the cutter
depth correction cam to a proper angle. Push the front knife upward and toward the cam.
Tighten screws.
Note---The blade under installation is normally pushed to the bottom, of course with
a tolerance actually. If the tolerance is too big in cutting thin wires, there will be a
circumstance where the cutter depth is reasonable at one side but too deep or shallow at
the other side, which will lead to poor effect of stripping or disagreed total length. After
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change of blade, the operator must check whether the opening of stripping knife edge is
the same at both sides.
This machine is designed to have cutter depth correction cam. Close the stripping knife
edge till a small gap, and watch with eyes if the gap heights of front knife and rear
knifeare the same. If it is required to adjust the height of knife edge, loosen the fixing
screws on front knife and the set screws at the right of cutter depth correction cam.
Rotate the cutter depth correction cam to a proper angle. Push the front knife upward
and toward the cam. Tighten screws.
4-2. Maintenance
※Before operation, the operator is sure to do inspection and fuel feeding.
During fuel feeding, please cut off the master power switch, to avoid dangers due to starting the
machine by mistake.
※Forbid the table top from being cleaned with high-pressure air rifle,in case a cut of wire
jacket dropping into the mechanism impacts normal operation.
V. Failures and solutions
5-1. Table of failures and solutions
Failures
A.
Disagreed
length of electric
wire
Causes
Solutions
Feed roller pressure is too low;
Adjust feed roller pressure or increase the
Cutter depth is too shallow;
depth;
The wire core is scratched by stripping Increase the opening of tool retracting; or
knife; or
Adjust heights of stripping knifes at both
Two stripping knifes are different in sides to make them the same
height
B. Scars on the Feed roller pressure is too low; or
jacket of electric Gaps are too small between sending Adjust feed roller pressure or clamp gap
wire
clamp, soldering clamp, wire clip, etc.
Cutter depth is adjusted improperly;
C. Poor stripping
Adjust cutter depth to the proper
opening of tool retracting is too large; position;
A blade is worn; or
Replace blades by new ones; or
Gaps are two big between pressure Shorten the gas between pressure wires
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26
wires
D. Broken wire
core
by referring to Fig. 5-A
Cutter depth is adjusted improperly;
Adjust cutter depth to the proper
position
pressure wire height limit
spring conduit
pressure wire conduit
Put electric wires through the wire pressing tube. The cylinder goes up during front stripping。
Crimpelectric wires to ensure they won’t move during stripping.
Adjust wire gap, as the case may be, by loosening and tightening the set screws limiting pressure
wire height. The lower screws are, the bigger the gap is.
A too big gap may cause loose crimping and slipping of electric wires, which will impact the total
length.
A too small gap may lead to indentation on the surface of electric wires
5-2. Table of errors and troubleshooting methods
S/N
Indication of error
1
Emergency Stop-
Troubleshooting
Gently rotate the emergency stop button clockwise till it bounces up,
so as to release the state ofEmergency Stop
2
Complete total
Total finished >= Total quantity, the machine stops automatically.
Please reset the value
3
Per bundleStop-
Press Start again and continue operation
4
Not at ORG
Before operation, the machine must return to the origin first.
5
F-X position Err
Check if the drive mechanism bears abnormal load or if two sensors
are impacted by foreign matters.
6
R-X position Err
Check if the drive mechanism bears abnormal load or if two sensors
are impacted by foreign matters.
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27
7
F-strip base Err
Check if the drive mechanism bears abnormal load or if the sensor
position is improper.
8
F-Pressabnormity
Switch off the power supply. Shake the terminal press wrench in Jog
mono-action function, to press the mold slowly. Observe the
matching of material with mold or the setting of terminal
detectionposition.
9
R-Press abnormity Same above
10
Detected
Wire Detect abnormities out by the sensor of Pre-Feed device wire pulling,
Abnormal
absence, andtenseness devices.
Check if the wire collector pressure is too high and if ingoing wires
pull each other.
11
R-Y position Err
Check if the drive mechanism bears abnormal load or if two sensors
are impacted by foreign matters.
12
Air
pressure
too If compressed air pressure is lower than 3.2 kgf / cm2, check air
low
13
14
supply.
Cutter_H
position Check if the drive mechanism bears abnormal load or if two sensors
Err
are impacted by foreign matters.
Rear wire clip Err
Check if the drive mechanism bears abnormal load or if the sensor
position is improper.
15
Pre-feed slow
Increase pre-Feeding Speed or reduce the Feeding Speed
16
F-X servo alarm
Check if the drive element bears abnormal load, and the driver will
display code
After the problem is solved, cut off the power supply for 3s. Restart
power supply.
17
R-X servo alarm
Check if the drive element bears abnormal load, and the driver will
display code
After the problem is solved, cut off the power supply for 3s. Restart
power supply.
18
F-X Axis over light Check if the drive mechanism bears abnormal load or if two sensors
are impacted by foreign matters.
19
R-X
light
Axis
over Check if the drive mechanism bears abnormal load or if two sensors
are impacted by foreign matters.
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28
20
Pre-Feeding Err
Check if Pre-Feed Wire Collector bears abnormal load or if ingoing
wires pull.
VI. Additional descriptive items
6-1. Variable-frequency noiseless terminal press:The internal variable-frequency control panel
isequipped with overload protection. If variable-frequency noiseless terminal press stays in the
state ofoverload protection for special reasons, the terminal press does not work. In this case,
cut off the power supply to terminal press, and wait for about10s till the capacitor
ofvariable-frequency control panel discharges the electricity fully. Then, switch on the power
supply. In the case ofoverload protection, cut off the power supply first. Rotate the plunger rod
for one cycle with wrench, and observe whether there is abnormal retardation. If there is,
remove it. Then start the machine again.
Default settings: dominant frequency F=70,Jog frequency D=5
Other parameters n=1, h=0, c=0, l=0
Do not change the default settings! Otherwise there will be a mismatch of speed or continuous
beat.
6-2. Transverse-mode terminal cutter: If the terminal press mold adopts transverse mode, the
cutting cycle can be set after terminal strips are fed into the cutter.
6-3.Description of special parameters: Enter the password of A1 level 1966 in Origin Windows,
and then you may change special parameters.
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a- Blade closed edge:Set the front feed roller to feed wires, and then close the knife edgeto
restrict the space for wire movement.
Default setting = 10
c- Blade Clamp:During wire clamping, close the knife edge further to restrict the space for wire
movement.
In this case, the knife edgeposition is wire core OD + Blade Clamp setting;
The higher the value is, the larger the opening of knife edge is. Default setting
=2.0
d-Bladeopen edge:the opening of knife edgeduring wire jacket stripping. The lower the value is,
the larger the opening of knife edge is.Default setting = 9
e-Sending ClampOpen Delay:wire clip holds wires and releases them to open sending
clamp.This is to set the sending clamp open time during wire delivery. Default setting =25
f-Rear Press Signal Advance:Sending of terminal pressing signals is before terminal
pressing. This setting indicates the advance time of pressing signals sending during R-X
Axis movement to crimping terminals. The lower the value is, the earlier signals are
sent.Default setting =70
g-Front Press Signal Advance:Sending of terminalpressing signals is before terminal
pressing. This setting indicates the advance time of pressing signals sending during F-X
Axis movement to crimping terminals. The lower the value is, the earlier signals are
sent.Default setting =70
h-[Rear clip delay]: Through this setting, the operator can adjust the delay of wire clip
clamp.
6-4.Description of terminal detector (SUNXFX-501digital optical fiber sensor):
Optical fiber sensor has 4 keys and two rows of digital display screens (top and bottom)
The top row displaysreference value of detection light source
The bottom row display 2 values: last measurement of the light sourceand maximum of given light
When electric wires or terminals pass by the light source, the measurement of light sourceis small
due to blockage.
For both terminal detection and detectionstripping detection, it is judged whether there is a
crimping terminal or broken wire core according to wires passing by block the light source. When
last measurement of the light source < reference value of detection light source,it is held that
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crimping terminals are normal or there is not a broken wire core during stripping.
Internal parameters are a lot. Do not change settings unless necessary, to avoid mistakes!
The operator should press the up key ▲ for increase setting and press the down key▼ to reduce
the value, in order for changing thereference value of detection light source.
Do not change other key functions that are not listed above, to avoid mistakes.
6-5.Additional description of conduits and pressure wire:
a-During processing of wires in
pressure wire
conduit
various sizes, it is required to
change suitable pressure wire
fixing
screws
conduits, spring conduits, and
spring positioning rings.。
Note: As shown in right figure, the
spring positioningring is the cutting
spring
positioning
ring
pressing
block
spring
conduit
opening. When screws are secured,
the spring positioning ring should
be able to press the spring conduits,
to avoid that abnormal wires push
conduits out and that the blade is damaged by spring conduits.
b-When wire pressing tube is changed, it should be noted thatthe gap is downward and aligned
withwire clips.Press Wire mono-action functions in Manual Windows can be tested during
locking.
6-6 Additional description of servo drive alarm:
Alarm
NO.
Content
Time
Description
Release
method
· Abnormity of control loop
0
1
System error
EEP data abnormity
After the
· Please consult the agent shop of our
control
company.
switch is
· Abnormity during parameter entry
ON
· Confirm wiring and enter the parameter
again
30
②
①
31
2
4
5
6
7
· Cannot read the machine type code
Machine code
· Check the motor and driver
abnormity
②
· Check wiring of encoder
Overspeed abnormity
· Abnormity of position control and speed
control
Speed deviation
· Adjust parameters
abnormity
Position deviation
After
· Confirm whether there are improper
abnormity
servo is
commands such as overspeed rotation and
Overload abnormity
ON
①
too short acceleration/deceleration
· Check the power cable of motor and
8
Command overspeed
wiring of encoder cable.
abnormity
· Confirm the brake has been released.
· The pulse output frequency of encoder is
Output frequency
9
Abnormity of encoder
pulse
After
over 4 Mpps.
control
· Check the output fractional-octave-band
switch is
value (parameters No.276.0, 278.0) of
ON
②
encoder.
· Check the number of encoder pulses
· The internal position command exceeds
the range of absolute value
(-1,073,741,823 ~ +1,073,741,823); or the
movement of one command exceeds the
range of -2,147,483,647 ~ +2,147,483,647.
Position command
10
overflow/
Origin restoration
failure
After
servo is
ON
· Origin restoration suspends or fails
· Check the use of internal position
command abnormity (parameter No.
①
643.0)
· Check the position and micro tuning of
positioning, and setting of movement in
trial running.
· Check parameter settings of origin
restoration.
11
Multi-ring counter
overflow of encoder
After
· Many data of encoder have exceeded the
control
specified value (32767).
switch is
· Check the selection of absolute system
31
②
32
ON
(parameter No. 257.0)
· Check to ensure the movement is within
32767 rounds.
·Over temperature abnormity of control
circuit.
12
· Decrease the environmental temperature
Over temperature
to lower than specification.
abnormity
· Set the driver according to the method
described in “3-1-5 installation direction
and gap description” in Chapter 3.
· Overvoltage abnormity of main control
14
circuit.
Overvoltage
abnormity
· Confirm the regenerated voltage warning
After
signals on setting panel, and install a
servo is
regenerated resistance if necessary.
ON
①
· Overvoltage or undervoltage abnormity,
AC200V abnormity, and continuous ON
regeneration of main power circuit.
· Check AC200V cable and wiring of
distribution cable in main power circuit.
15
Power abnormity
· Adjust AC200V input power and time of
servo ON according to the time order
drawing “5-1 and 5-2” in Chapter 5.
· Confirm the regenerated voltage warning
signals on setting panel, and install a
regenerated resistance if necessary.
· Data interruption of encoder
Communication
16
abnormity 1 of
encoder (data receipt
abnormity)
Communication
17
abnormity 2 of
encoder (no response)
· Check such problem as poor contact in
After
control
switch is
ON
wiring of encoder cables.
· Install FG, separation motor cable and
encoder cable, etc. for interruption
resistance.
· Communication interruption of encoder
·Check such problem as poor contact in
wiring of encoder cables.
32
②
33
· Install FG, separation motor cable and
encoder cable, etc. for interruption
resistance.
· If the encoder cable is too long, shorten
it. The recommended length is not more
than 20m.
· Abnormity of encoder
18
Encoder abnormity
· Please consult .the agent shop of our
company
19
Communication
· Cannot do initial communication with the
abnormity 3 of
encoder.
encoder
· Check the wiring of encoder.
(bi-directional
· If the encoder cable is too long, shorten
communication
it. The recommended length is not more
abnormity)
than 20m
· Temporary changes of data
·Check such problem as poor contact in
20
Multi-ring data
wiring of encoder cables.
abnormity
· Install FG, separation motor cable and
encoder cable, etc. for interruption
resistance.
· Temporary changes of data due to
21
voltage drop of encoder
Voltage drop
· Check if the battery voltage drops in
abnormity of encoder
③
absolute mode
· Check if the battery cable drops off.
Voltage drop
22
· Voltage drop of control power source
abnormity of control
(DC24V)
power
23
24
Blockage of basic
circuit
Overcurrent
abnormity
After
· No power supply to basic circuit
servo is
· Please consult the agent shop of our
ON
company
· Abnormity of control circuit
·Check if the motor power cable
grounding or UVM is improper, and check
33
①
34
the wiring of distribution cable for main
circuit power supply.
· If there is a sharp CCW/CW reverse
motion, extend the acceleration /
deceleration time and take measures like
command smoothing, to slow down the
motion.
25
Inverter abnormity 1
· Abnormity of control circuit
· Check if the motor power cable
26
Inverter abnormity 2
grounding or UVM is improper, and check
(servo ON time over )
the wiring of distribution cable for main
circuit power supply.
· Abnormity of sensor
27
Current sensor
abnormity
· Check the environmental temperature of
driver
· Please consult the agent shop of our
company
· Voltage drop of control power source
Voltage drop
29
abnormity of 5V
control power
(DC5V)
· Check if there is short circuit in wiring of
encoder cables
· Please consult the agent shop of our
company
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35