I/O CABLE SELECTOR OPERATING MANUAL. Molex Japan Co., Ltd. INSTRUCTION MANUAL NO. IS-8085E ISSUED REVISED

Transcription

1 INSTRUCTION MANUAL NO. IS-8085E ISSUED REVISED REV. 0 I/O CABLE SELECTOR ( :1.0mm Pitch I/O Cable Selector) ( : 1.27mm Pitch I/O Cable Selector) OPERATING MANUAL Molex Japan Co., Ltd.

2 Molex Japan Co., Ltd. Contents of Update Instruction Manual No. IS-8085JE Title I/O Cable Selector Tool Number Rev. Issued Description /07/14 New creation release. ECN-JM Prepared by Y. Ishiwata Checked by T. Yoshida Approved by A. Horino

3 Table of Contents <Safety Precautions> Page 1. Introduction...A-1 2. To operation supervisors...a-1 3. Dangerous operations...a-1 4. Careful handling...a-2 5. Installation site...a-2 <Quality Precautions> 1. Introduction...B-1 2. Must be carried out...b-1 3. Must not be carried out...b-1 1. Description Machine Configuration and Applicable Products 2.1. Machine Name and Configuration Applicable Connector and Wire for 1.0mm Pitch Machine Applicable Connector and Wire for 1.27mm Pitch Machine Machine Appearance and Main Name Circuit Number Assignment Circuit Number Assignment Specifications 3.1.Machine Specifications Power Source Specifications Outer Dimensions and Weight Operating Environment Conditions Installation Space Machine Installation and Preparation 4.1.Installation of Machine Adjustment of Table Switch of Display Character Switch of Circuit Number Assignment Operation Method 5.1. Wire Arrangement Flow Name of Wire Arrangement Part End Processing of Cable Installation of Cable Kinds of Wire Arrangement Setting of Wire Arrangement Pattern Number Master Wire Arrangement Flow of Master Wire Arrangement Conduction Wire Arrangement Flow of Conduction Wire Arrangement Circuit number Input Wire Arrangement Advancement and Retreat Wire Arrangement Wire Arrangement of Twisted-pair Wire Notes of Wire Arrangement Wire Arrangement Pattern Data Creation and Check 6.1. Memory Mode Creation and Registration of Wire Arrangement Pattern Data Input Error at Registering...25

4 Table of Contents 6.4.Wire Arrangement Data Clearing Memory Check Wire Arrangement Pattern Input Procedure 7.1. Example of Inputting Conduction Wire Arrangement Example of Inputting Master Wire Arrangement Confirmation of Wire Arrangement Data Maintenance and Check 8.1. Daily Maintenance Check of Machine Exchange Method of Pusher Adjustment Method of Original Position Exchange Method of Switches Exchange method of Ten-key Version of Software Initialization of EEPROM Connected Parts of Switch and Sensor Trouble Shooting Other Error Message and Action Method Circuit Diagram Parts List 9.1.Parts Development Parts List of 1.0mm Pitch Machine Parts List of 1.27mm Pitch Machine Startup Checklist...55

5 <Safety Precautions> Please read the following before operating the machine. A 1 1. Introduction Thank you for choosing our I/O Cable Selector. This instruction manual is prepared so that the machine is properly used. Please take the time to read this manual, making sure you understand the operating procedures described herein before attempting to operate the machine. 2. To operation supervisors 1) Operators should fully understand the contents of this manual before operation. 2) If operators do not understand English, translate this manual into the proper language. 3) Keep this manual near the machine so that operators can refer to it anytime. 3. Dangerous operations Observe the following precautions to prevent a life-threatening accident. 1) Don t insert a part of your body or other foreign materials into the machine when it is running. 2) Don t place the machine on an unstable, off-balanced worktable from which the machine might fall down. 3) If more than two operators are engaged in operation or checkup at the same time, even slight miscommunication might lead to a serious accident. 4) Don t put your face too near the operation area while this machine is operating, as flying fragments may hurt you seriously. Caution 1) Unauthorized reproduction of this document in part or in whole is prohibited. 2) The contents of this document are subject to change without notice. 3) Molex Japan Co., Ltd. assumes no responsibility for losses resulting from use or misuse of this document.

6 <Safety Precautions> Please read the following before operating the machine. A 2 4. Careful handling Keep the items below to use the machine safely and properly. * Please contact our application-tooling group if something s wrong with the machine. 1) Replacement and checkup of the parts When you have to put your hands inside the machine to replace or check the parts, confirm in advance that unplugging the power cable. 2) Don t touch the internal electric circuit Don t remove the safe cover of this machine during operation. The electric circuit is included in this place, and it is not only dangerous, but it will become the cause of failure if a hand is touched. 3) Malfunctions If you notice any unusual sound or movement in the machine, stop the operation immediately and check the suspicious parts. 4) Foreign materials If foreign materials such as water or metals accidentally get inside the machine, stop the operation immediately and remove those materials. 5. Installation site Be careful about the following items when you install the machine. 1) Temperature and humidity Don t operate the machine in extremely high/low temperature or extremely high humidity. * Place it where the temperature is stable around 23 degrees centigrade and the air is well ventilated. 2) Dust and corrosive gas It will become the cause of failure if dust, corrosive gas, etc. are in the circumference of this machine. * Please don t install this machine to such a place. 3) Near electromagnetic sources If the machine is used near a surge generator or powerful electromagnetic source, there is a possibility of carrying out incorrect operation. * Please don t operate this machine in such a place. 4) In place where unstable power sources The machine may incorrect-operate in the place where change of power supply voltage is sharp beyond a specification value. * Please don t install this machine in such environments.

7 <Quality Precautions> You surely carry out the following for defect-free production. B 1 1. Introduction In order not to produce a defective article with this machine, this chapter has described Must be carried out, and Must not be carried out as an important matter on operation. Keep in mind that there is a possibility that a defective article will be produced when not protecting this. 2. Must be carried out Please be sure to perform the following matter to maintain product quality. 1) Enforcement of startup check Please check the machine in accordance with the startup checklist described in this document before an operation start, and start operation after confirming nothing is wrong with the machine. * If the check is neglected, there is a possibility that a defective article will be produced. 2) Confirmation of quality Please start the production after confirming the quality of a product picked up from the first operation, and it passes all of the claims required in the I/O cable specification of a corresponding connector. * It is recommended to initiate the operation on the preferable condition that enough margins for the standard are identified. 3. Must not be carried out Please don t perform the following matter by any means to maintain product quality. 1) Using of unqualified I/O cable Please don t use an unqualified I/O cable. There is a possibility of causing connector breakage and termination defect by mismatching of a wire outer diameter. * Please operate using a qualified I/O cable. 2) Pushing a wire too much deeply Don t push a wire too much deeply. It may lead to the breakage of an upper cover and a pusher. * Please operate the machine in the appropriate amount of the wire pushing. 3) Wire cutting in a defective state When cutting the wire is defective, and the shear drop exceeds the outside diameter of the wire insulation, the use of the machine is a prohibition because there is danger of short-circuits. * Please improve a wire defective cutting promptly.

8 Page 1 1. Description This machine is an electric semi-automatic wire arrangement machine that arranges the wire to the upper cover of 1.0mm pitch or 1.27mm pitch I/O connector of Molex. Two types are available, (1) one is 1.0mm pitch I/O cable selector and (2) the other is 1.27mm pitch I/O cable selector. As a feature, Master wire arrangement arranged in circuit number order and Conduction wire arrangement that arranges by taking conduction on the other side of the cable with the one side connector can be selected. It is possible to arrange the wire from 10-circuit to 100-circuit mechanically by adjusting the position of the holder. 2. Machine Configuration and Applicable Products 2.1. Machine Name and Configuration 1) Machine name and number: (1) : 1.0mm Pitch I/O Cable Selector (2) : 1.27mm Pitch I/O Cable Selector 2) Machine configuration: (1) Machine main unit (2) Connector box One type of specified circuits is including the standard configuration for conduction wire arrangement Applicable Connector and Wire for 1.0mm Pitch Machine 1) Connector: Molex 1.0mm pitch I/O connector (** = Circuit number) **11: **P Plug Assembly kit (Plug + Upper cover) 2) Wire: UL20276 AWG#28 Multi-wire braid shield cable, or other Molex qualified cables. Insulation diameter = phi0.50mm- phi0.58mm, Cable outer diameter = phi7.0mm or less 2.3. Applicable Connector and Wire for 1.27mm Pitch Machine 1) Connector: Molex 1.27mm pitch I/O connector (** = Circuit number) **11: **P Plug Assembly kit (Plug + Upper cover) 2) Wire: UL20276 AWG#28 Multi-wire braid shield cable, or other Molex qualified cables. Insulation diameter = phi0.50mm- phi0.58mm, Cable outer diameter = phi9.0mm or less

9 Page Machine Appearance and Main Name Connector box Table Insertion guide Conduction blade LCD Ten-key

10 Page Circuit Number Assignment Circuit number assignment Standard/Zigzag of the machine can be switched from the operation panel. * Please refer to Switch of circuit number assignment of this document for the procedure. Note The circuit number assignment set by the above-mentioned is held even if it turns off power. 1) 1.0mm pitch machine Standard circuit number assignment Zigzag circuit number assignment [Left] [Right] [Left] [Right] (n/2)+1 (n/2) n-1 n Cable (n/2)-1 n/2 n-2 n Cable n-3 n-1 [Operator] [Operator] 2) 1.27mm pitch machine Standard circuit number assignment Zigzag circuit number assignment [Left] [Right] [Left] [Right] (n/2)+1 (n/2) n-1 n Cable (n/2)-1 n/2 n-2 n Cable n-3 n-1 [Operator] Concave mark [Operator]

11 Page Operation Panel (!) Mode change switch: The wire arrangement mode and the memory mode are switched. (2) [SET/START] switch: The set position and the wire arrangement work position (original position) are switched. (3) [RESET] switch: Work is interrupted and the power supply is reset. (4) Ten-key: Various conditions in the cloth line mode and the memory mode are input. (5) LCD monitor display: Various information such as the necessary condition and present location in each mode is displayed. (6) Connector box: It uses it for the input side port of conduction wire arrangement. (7) Power switch: The power supply is done on off. (8) Power socket: It connects with AC100V through the power cable of the attachment. (10) Earth terminal: The earth wire is connected. (The malfunction by the noise etc. is prevented) [Front] [Rear]

12 Page 5 3. Specifications 3.1. Machine Specifications 1) Sheath strip length: 80mm or more (10-circuit to 36-circuit) 100mm or more (50-circuit to 100-circuit) 2) Minimum cable length: 350mm or more: It can be connected to the connector box directly. 100 to 350mm: The relay box and the relay cable of the option are necessary. 3) Wire arrangement possible circuit number: 10-circuit to 100-circuit 4) Operation mode: Two kinds of wire arrangement mode and memory mode. (It switches with the key switch of the operation panel) 5) Wire arrangement mode: Master wire arrangement, Conduction wire arrangement and Circuit number input wire arrangement * Master wire arrangement is the standard mode. (The mode specification cannot be done) * When the conduction wire arrangement or the wire arrangement through circuit number input has been taken, the operation mode will be switched to its mode automatically. 6) Master wire arrangement: 7) Management of wire arranged circuit number: 8) Conduction wire arrangement: 9) Circuit number input wire arrangement: It sequentially displays from the smallest circuit number of the wire arrangement pattern in the LCD, the table is moved to the position, and the LED on the wire insertion side is lit. (For wire arrangement of one side open cable) Method to save the wire arrangement circuit number in the work memory, and to erase the circuit number at each wire pushing operation. The circuit number of the wire that takes the conduction is displayed in the LCD, the table is moved to the position, and the LED on the wire insertion side is lit. (For wire arrangement of cable with one side connector) The circuit number that inputs ten keys is displayed directly in the LCD, the table is moved to the position, and the LED on the wire insertion side is lit. (For restart or partial wire arrangement on the way) 10) Cycle time: Approx. 1 second per wire (Not including any operation time of a worker) 11) Operation panel: Arranged in the front panel of the machine. (Ten-key, function keys, and mode switch)

13 Page 6 12) Display: LCD (Liquid Crystal Display) of 20 characters x two rows display (Alphabet, numbers and Kana) 13) Switch of display character: The display character Japanese/English can be switched from the operation panel. 14) Memory mode: Wire arrangement pattern making, memory check, and parameter input (For memory access) 15) Wire arrangement pattern making: It makes with the ten-key of the operation panel and uses after registering to the memory. 16) Memory capacity: 200 patterns or less can be memorized. (Setting, memory, and call from operation panel) 17) Connector box: It mounts for the conduction wire arrangement of the cable with the one side connector by the method that can be exchanged for a right side of the machine. * It is necessary to change to acceptable goods to differ in each circuit number according to the model. 18) Relay box (option): For the conduction wire arrangement of cable length 100mm to 350mm. It connects with the connector box of the main body through the relay cable. * It is necessary to change to acceptable goods to differ in each circuit number according to the model. 19) Relay cable (option): L=500 mm (1:1 connecting) cable of both ends plug that connects connector box of main body with relay box. * It is necessary to change to acceptable goods to differ in each circuit number according to the model. 20) Change over of each circuit number: 21) Conduction detection method: 22) Wire arrangement of twisted-pair wire: 23) Productivity (Reference value): It is necessary to adjust the set positions of the upper cover and cable, and to exchange for the acceptable connector box. The method is that an operator holds a wire to the conduction blade of the machine. The conduction blade penetrates through the insulation of the wire and contacts with the conductor, and the conduction is detected. It is a simultaneous wire arrangement function in the same position of a right and left as for the twisted-pair wire. This is possible in the master wire arrangement mode. Approx. 160 seconds per wire arrangement of 26-circuit * The preprocessing time of the cable doesn t contain it.

14 Page Power Source Specifications 1) Power supply: AC100V +/-10%, 50/60 Hz, 150VA or less 3.3. Outer Dimensions and Weight 1) Outer dimensions: 310 (width) x 545 (depth) x 220 (height) mm 2) Weight: Approx. 15kgf 3.4. Operating Environment Conditions 1) Operating ambient temperature: 5-35 degrees centigrade (Away from direct sunlight) 2) Operating ambient humidity: 35% - 85% RH (No condensation) 3) Operating atmosphere: Atmosphere should be free of corrosive gases and contaminants such as dust or lint. 4) Voltage variation: Within +/- 10% of the rated voltage 5) Grounding: Ground the earth terminal surely Installation Space Machine installation space required for the purposes of performing operation and maintenance checkups. (On the work desk of 700mm - 750mm height) 900 (width) x 900 (depth) x 1600 (height) mm

15 Page 8 4. Machine Installation and Preparation 4.1. Installation of Machine 1) Set the front panel of the machine to the edge of a solid worktable and arrange the machine, and check the stable installation without shakiness. 2) Install the connector box of the attachment in a right side of the machine. 3) Connect the earth wire to the earth terminal in the back. 4) Turn off the power on/off switch and connect the power cable of the attachment with the AC100V outlet. Worktable Cable 4.2. Adjustment of Table 1) Set the used upper cover (1) in the stage (2) of the table, and adjust the sleeve holder (4) to hold it with the hook (3). 2) Adjust the cable holder (5) position similarly at the central position of the upper cover (1). Stopper Cable holder (5) Stage (2) Sleeve holder (4) Stopper Upper cover (1) Sleeve holder (4) Hook (3) Parallel

16 Page Switch of Display Character Display character Japanese/English can be switched by the following operation. 1) Switch to the [WORK] side after switching <Wire arrangement mode main screen> the mode change switch to the [MEMORY] P t n N o P 2 0 P side. P i n N o. [ ] 2) Push the [SFT] key on the wire arrangement mode main screen, and the keyword input screen opens. 3) Input the following figure and fix it with the [ENT] key. (1) Japanese Display: Input 111 (2) English Display: Input 222 <Keyword input> K e y w o r d N o. I n p u t! N o. [ ] 4.4. Switch of Circuit Number Assignment Circuit number assignment Standard/Zigzag can be switched by the following operation. 1) Switch to [WORK] after switching the mode change switch to the [MEMORY] side. 2) Push the [SFT] key on the wire arrangement mode main screen, and the key word input screen opens. 3) Input the following figure and fix it with the [ENT] key. (1) Standard assignment: Input 333 (2) Zigzag assignment: Input 444 <Wire arrangement mode main screen> P t n N o P 2 0 P P i n N o. [ ] <Keyword input> K e y w o r d N o. I n p u t! N o. [ ] <Zigzag arrangement screen> P t n N o P 2 0 P Z i g z a g P i n N o. [ ]

17 Page Operation Method 5.1. Wire Arrangement Flow (Outline) The master (opening) wire arrangement of the operation mode is basic. It automatically changes into the conduction wire arrangement mode of being able detecting the conduction of a wire. Power supply ON Turn on the power on/off switch. Pattern registration Register newly for unregistration a wire arrangement pattern. Pattern number input Input the wire arranged pattern number. Table drawn out The table comes out when the [SET/START] switch is pushed. Set of upper cover Set an upper cover in the table in the prescribed direction. Set of cable Set a cable in the cable holder of the table. Table return The table is returned to the wire arrangement position pushing the [SET/START] switch. Master wire arrangement Arrange a wire displayed in the LCD in the insertion guide on the LED lighting side. Conduction wire arrangement The table moves to the detection circuit number position when a wire is held to the conduction blade, and then the wire is arranged in the insertion guide on the LED lighting side. Wire arrangement end The table comes out in the operator side when all the wire arrangement ends. Cable taking out Take out the wire arranged cable assembly from the table.

18 Page Name of Wire Arrangement Part Conduction blade Left LED Right LED Left insertion guide Stopper Right insertion guide Wire guide comb Hook Table Cable clamp

19 Page Processing of Cable End 1) Removal of cable jacket The jacket of a cable with the specified length is removed. (1) For 10 to 36-circuit: L = 80mm or more (2) For 38 to 100-circuit: L = 100mm or more Protection paper A B Cable L Cupper foil tape Braid shield 2) Processing of shield The braid shield is cut by a specified size, and after it turns to the sheath side, the copper foil tape of specified width is wrapped 1.5 times on it. And the protection paper is cut at the sheath edge. * Copper foil tape: Type 2245 of Sumitomo-3M or equivalent. (1) 1.0mm pitch cable specification: A = 1mm, B = 6mm (Tape width) (2) 1.27mm pitch cable specification: A = 1mm, B = 12mm (Tape width) 3) Grouping of wire The twist of wires is taken off carefully and it divides into two groups of the following. No. Wire group 1 Left wire arrangement wire 2 Right wire arrangement wire

20 Page Installation of Cable 1) The table moves to the operator side when the [SET/START] switch is pushed after tuning on the power on/off switch. 2) Match the sheath edge of the cable to the stopper (1), and clamp the cable (2) with the cable holder (3) in the state. Stopper (1) Cable holder (3) Cable (2) 5.5. Kinds of Wire Arrangement The method of the wire arrangement has four kinds of the following. 1) Master wire arrangement: This is a basic operation mode of the machine. The table moves in order with a small circuit number of the registered pattern. 2) Conduction wire arrangement: 3) Circuit number input wire arrangement: 4) Advancement and retreat wire arrangement: The table moves to the detection circuit number position when the conduction is detected pushing a wire the conduction blade in the master wire arrangement mode and the LED on the wire arrangement side is lit. The table moves to the circuit number position input directly with ten keys. However, a circuit number that doesn t exist in the wire arrangement data cannot be input. The table moves back and forth by one pitch when the [+/-] key is pushed. However, a circuit number that doesn t exist in the wire arrangement data cannot be arranged.

21 Page Setting of Wire Arrangement Pattern Number It is necessary to register the wire arrangement pattern number when the wire arrangement work is done. When the machine is shipped, the wire arrangement pattern of [1:1] connecting wires of same circuit number as the connector box is set to pattern No.1. 1) The mode change switch is switched to the [WORK] side, and the power on/off switch is turned on. 2) It changes into the wire arrangement main screen after the start message is displayed for three seconds, and the pattern number at power supply OFF is displayed. * When it is not necessary to change the pattern number, push the [SET/START] switch. 3) The screen changes into the pattern number input demand screen if the [INP] key is pushed when the change in the pattern number is a necessity. Pattern number is chosen from the lower display, input, and it fixes with the [ENT] key. <Start message> m m S e l e c t o r B y M O L E X <Wire arrangement mode main screen> P t n N o P 2 0 P P i n N o. [ ] <Pattern number input demand screen> P t n N o. I n p u t! [ ] N o. : 1, 2, 5, 1 1, 2 1, 3 5 <Pattern number input screen> P t n N o. I n p u t! [ 2 ] N o. : 1, 2, 5, 1 1, 2 1, 3 5 * Please input again after it cancels once with the [CLR] key and fix it when you make a mistake in the input. <Pattern number 2 screen> P t n N o P 2 0 P P i n N o. [ ] * The display of the lower can be confirmed with the [+/-] key.

22 Page Master Wire Arrangement Master (opening) wire arrangement is done to one side of the cable. 1) The table moves to the set position of the operator side when the [SET/START] switch is pushed. 2) Set an upper cover (1) and a cable (2) at each position of the table (3). 3) The table moves to the smallest circuit number position when the [SET/START] switch is pushed again, a circuit number is displayed in the LCD, and the LED on the wire arrangement side is lit. <Table set position> P t n N o P 2 0 P P i n N o. [ S E T ] <First wire arrangement position> P t n N o P 2 0 P P i n N o. [ ] <Second wire arrangement position> P t n N o P 2 0 P P i n N o. [ 0 0 ] 4) Arrange a wire (4) while strung according to the insertion guide (6) on the LED lighting side (5). 5) The arranged wire is automatically press-fitted to the upper cover, and the excess wire is cut on the upper cover edge. 6) After press-fitted, the table moves to the next wire arrangement position and displays the circuit number in the LCD. 7) The table automatically returns to the set position when all the wire arrangement data ends repeating the above-mentioned. LED lighting side (5) Wire (4) Cable (2) Table (3) Upper cover (1) Insertion guide (6)

23 Page Flow of Master Wire Arrangement Input the arrangement pattern number 1) Work setting Push the [SET/START] switch Table moves to the set position Min. 80mm Set a connector and a cable Push the [SET/START] switch again 2) Wire arrangement operation Table moves to the smallest circuit number position Arrangement side LED is lit Strung wire Arrange a wire to LED lighting side Execution of press fitting and cutting 3) Cable taking out All arrangement ends? Yes No Table moves to the next position Table returns to the set position Take out the cable assembly

24 Page Conduction Wire Arrangement Conduction wire arrangement can be done on the opposite side of the cable with the one side connector. 1) Connect the connector in the one end of the cable with the connector box. 2) When an upper cover (1) and a cable (2) are set in the table (3), and the [SET/START] switch is pushed, the table moves to the wire arrangement smallest circuit number position. 3) The confirmation sound of Pi is emitted when one arbitrary wire (4) is pushed to the conduction blade (7), and the table moves to the detection circuit number position. <Set position> P t n N o P 2 0 P P i n N o. [ S E T ] <Smallest circuit number position> P t n N o P 2 0 P P i n N o. [ ] <Conduction circuit number position> P t n N o P 2 0 P P i n N o. [ ] 4) Arrange a wire (4) while strung according to the insertion guide (6) on the LED lighting side (5). 5) The arranged wire is automatically press-fitted to the upper cover, and the excess wire is cut on the upper cover edge. 6) The table automatically returns to the set position when all the wire arrangement data ends repeating the above-mentioned. Conduction blade (7) LED lighting side (5) Cable (2) Wire (4) Table (3) Upper cover (1) Insertion guide (6)

25 Page Flow of Conduction Wire Arrangement Input the arrangement pattern number Press the [SET/START] switch Table moves to the set position Set a connector and a cable Press the [SET/START] switch again Table moves to the smallest circuit number position No All arrangement ends? Push a wire to the conduction blade Yes No NG buzzer Detected? Yes Table returns to the set position Take out the cable assembly Table moves to the detection circuit number position Arrange the wire to LED lighting side Execution of press fitting and cutting

26 Page Circuit Number Input Wire Arrangement The wire arrangement to input directly the circuit number that wants to be arranged with the ten-key is possible. 1) Input the circuit number that wants to be arranged with the ten-key in the state of the wire arrangement mode screen. 2) The table moves to the specified circuit number position when the input value is fixed with the [ENT] key. 3) Confirm the circuit number in the LCD, and arrange a wire to the LED lighting side. * The NG buzzer rings when an unregistered circuit number in the arrangement data is inputting fixed, and <NG> is displayed. The wire arrangement cannot be done. <Circuit number input> P t n N o P 2 0 P P i n N o. [ 1 6 ] <Circuit number fixed> P t n N o P 2 0 P P i n N o. [ ] <Over of total pins> P t n N o P 2 0 P < N G! > P i n N o. [ ] * It doesn t accept more than the total pins of the connector Advancement and Retreat Wire Arrangement The table is moved with the [+/-] key and the wire arrangement is also possible. In this case, the moving range does only in the wire arrangement area though the table moves the endless loop regardless of the presence of the circuit number registration. However, a circuit number that doesn t exist in the wire arrangement data cannot be arranged. * When the [+/-] key is kept pushed, it becomes a dash movement (high-speed movement).

27 Page Wire Arrangement of Twisted-pair Wire Please do the wire arrangement work according to the following procedures when you arrange the twisted-pair wire to right and left simultaneously. 1) Untwist a pair Untwist a pair Arrange one side of pair to LED turning off side NG buzzer sounds and an error is displayed Arrange the other of pair to LED lighting side 2) Arrange a wire to LED turning off side Execution of press fitting and cutting of pair 4) Press fitting of both at the same time 3) Arrange the other wire to LED lighting side

28 Page Notes of Wire Arrangement 1) Possible or impossible of wire arrangement It can be judged whether the wire arrangement is possible from the LED lighting (possible) and turning off (impossible). 2) Wire arrangement cannot be done to the same place twice. The LED is turned off when arranging a wire once at the LED lighting position and continuous arrangement at the same position cannot be done. * The wire arrangement circuit number is saved in the work memory, and a double wire arrangement is prevented by the method to erase the circuit number at each wire press fitting operation. 3) When you make a mistake in wire arrangement. A right screen is displayed with the NG buzzer when arranging a wire on the reverse-side (LED turning off side), and please does over again. <Error when arranging to other side> A r r a n g e t o l e f t! P i n N o. [ ] 4) Strung of wire Please arrange a wire while strung. There is a case that the wire doesn t exactly enter the upper cover when arranging with the wire made to slacken. 5) When you cancel work on the way. When the work is canceled on the way, the [RESET] switch is pushed. The power supply resets and the machine returns the initial. Note Please note that the circuit number data that has been arranged while operating disappears in this case, too.

29 Page Wire Arrangement Pattern Data Creation and Check The mode change switch is switched to [MEMORY], the wire arrangement pattern data is input with the ten-key according to the screen display, and it fixes it Memory Mode When the mode change switch is switched to [MEMORY], the memory mode menu screen is displayed. <Memory mode menu> [ C H K ] > M e m o r y C h e c k [ I N P ] > P a t t e r n I n p u t 1) Memory check: The content of the wire arrangement data is displayed on the LCD. 2) Pattern input: Making and deletion of wire arrangement data. 1. Input: The wire arrangement data is made with ten-key. 2. Memory clearness: Deletion of registered wire arrangement data. <Memory Mode> <Memory check> <Pattern input> Pattern number setting <Input> <Clearness> Parameter data list Connecting data list Pattern number setting Switch with the [ENT] key. Parameter data input Wire arrangement data input Wire arrangement data clearness

30 Page Creation and Reiteration of Wire Arrangement Data When the wire arrangement work is done, it is necessary to create and to register the wire arrangement pattern data. It explains the procedure in this paragraph. 1) Push the [CHK] key on the memory mode menu screen, and the wire arrangement data input selection screen is opened. 2) Input 1, and the pattern number input demand screen is opened. 3) Input an unused pattern number, and fix it with the [ENT] key. (The lower is a display of the registered pattern number) 4) Input the total pin number of the wire arrangement side connector in the figure, and fix it with the [ENT] key. (Range of number of total pins: 10 to 100) 5) Input the total pin number of the input side connector (connector box side), and fix similarly, too. (Range of number of total pins: 10 to 100) * Please cancel the input mistake with the [CLR] key, input with the ten-key again, and fix it. 6) Input the connector name repeating that it fixes with the [ENT] key looking for one character with the [+/-] key. (Eight characters or less) When the [ENT] key is pushed twice, the connector name is registered. 7) The pin number on the wire arrangement side is input based on the pin number on the input side (connector box side) and the wire arrangement data input is fixed sequentially with the [ENT] key. 8) The same as the pin number on the input side is input at open wire arrangement. <Memory mode main> [ C H K ] > M e m o r y C h e c k [ I N P ] > P a t t e r n I n p u t <Arrangement data input selection> A r r a n g i g d a t a I n p u t 1 : I n p u t 2 : C l e a r <Pattern number input> P t n N o. I n p u t! [ 3 ] N o. 1, 2, < Number of arrangement side total pins> N u m b e r o f T o t a l P i n s < A r r a n g e > P i n [ 2 0 ] <Number of Input side total pins> N u m b e r o f T o t a l P i n s < I n p u t > P i n [ 2 0 ] <Connector name> C o n n e c t o r N a m e N a m e [ 2 0 p 2 0 p ] <Wire arrangement data input waiting> P t n N o > [ ] Input side > Arrangement side <No.1 pin is connected with No. 15 pin> P t n N o > [ 1 5 ] Input side > Arrangement side

31 Page 24 9) It becomes an empty circuit number (no wire arrangement) when fixing with the [ENT] key without the figure. 10) Resister it in the memory pushing the [INP] key when all the input is completed. It returns to the memory mode menu screen after the completion message is displayed for a few seconds. <Registration completion> P t n N o. 3 I n p u t C o m p l e t e d! * Please push the [RESET] switch when you want to cancel on the way. The input data is abandoned and returns to the memory mode menu screen. Note If the [INP] key is not pushed at the end, the created data is not registered.

32 Page Input Error at Registering When the following errors occur at registering, the NG buzzer rings and it becomes a data input demand screen with an error message. Please register again the [INP] key pushing after restoring the error part. 1) When dual data exists. There are two same wire arrangement circuit number or more. * The display of dual data displays the second data. 2) When data more than the number of total pins exists. The wire arrangement circuit number is larger than the number of registered total pins. <Dual data error> P t n N o. 3 D u a l d a t a! > [ ] * Another has wire arrangement circuit number 001. <Over of total pins> P t n N o. 3 E x c e s s i v e! > [ ] * Registered total pins = 20 < 21 * Please push the [RESET] switch when you want to cancel on the way. The input data is abandoned and returns to the memory mode menu screen.

33 Page Wire Arrangement Data Clearing When the registered wire arrangement pattern is cleared (deleted), it does according to the following procedures. 1) If 2 is input with the ten-key on the wire arrangement input selection screen, it becomes this mode. 2) Because the pattern number input demand screen is displayed, cleared pattern number is input with the ten-key and it fixes with the [ENT] key. 3) The wire arrangement data fixed to push the [ENT] key by blinking Data clear OK? is cleared, this mode is ended after a clear screen is displayed for three seconds, and it returns to the memory mode menu screen. <Arrangement data input selection> A r r a n g i g d a t a I n p u t 1 : I n p u t 2 : C l e a r <Pattern number input demand> P t n N o. I n p u t! [ 2 1 ] N o. 1, 2, 5, 1 1, 2 1, 3 5 <Confirmation of clearing pattern> P t n N o. 2 1 D a t a C l e a r O K? * This mode is canceled when the [CLR] key is pushed, and it returns to the memory mode menu screen. * When the pattern number of unregistration is input, the warning screen of an unregistered pattern is displayed. It returns to the pattern number input selection screen when the [ENT] or the [CLR] key is pushed in the state. <Execution of clearing pattern> P t n N o. 2 1 D a t a C l e a r!! <Warning of unregistered pattern> P t n N o. 2 1 N o t E n t r y D a t a O K?

34 Page Memory Check The content of the registered wire arrangement pattern can be confirmed in this mode. 1) It becomes this mode if the [CHK] key is pushed on the memory mode menu screen, and it becomes a pattern number input demand screen. <Memory mode menu> [ C H K ] > M e m o r y C h e c k [ I N P ] > P a t t e r n I n p u t 2) After pattern number is input with the ten-key, it fixes with the [ENT] key because pattern number that can be input to the lower is displayed. <Pattern number input demand> P t n N o. I n p u t! [ ] N o. 1, 2, 5, 1 1, 2 1, 3 5 3) Then, the content of connecting wires is displayed in the LCD. The content of connecting wires is confirmed pushing the [+/-] key. <Pattern number input> P t n N o. I n p u t! [ 3 5 ] N o. 1, 2, 5, 1 1, 2 1, 3 5 4) It becomes a display of the parameter data if the [ENT] key is pushed, and various parameter data can be confirmed similarly with the [+/-] key. It returns to the content of connecting wires display when the [ENT] key is pushed again. 5) This mode ends with the [CHK] key or the [CLR] key, and returns to the memory mode menu screen. < Data of connecting wires display> P t n N o > [ ] < Number of arrangement side total pins> N u m b e r o f P i n < A r r a n g e > P i n [ 035 ]

35 Page Wire Arrangement Pattern Input Procedure 7.1. Example of Inputting Conduction Wire Arrangement [Example of Pattern] [Input side] [Wire arrangement side ] (Connected side in the connector box) (Wire arrangement side in the future) This side is input. The pattern input and the registration procedure of the above-mentioned conduction wire arrangement is shown. <Input example> Pattern number: 10, Connector name: 26P-26P Key switch Switch the mode change switch to the [MEMORY] side. Mode selection Push the [INP] key. Input mode Input 1, and the pattern input is specified. Pattern number Input 10, and fix the pattern number 10 with the [ENT] key. Number of wire arrangement side total pins Input 26, and fix the number 26 of wire arrangement side total pins with the [ENT] key. Number of input side total pins Input 26, and fix the number 26 of input side total pins with the [ENT] key.

36 Page 29 Connector name Data of connecting wires Input 2 and push [ENT] key, and, and input P and push [ENT] twice, and the connector name of 26P-26P is fixed. * The character input is fixed with the [ENT] key while looking for one character pushing the [+/-] key. * It proceeds to the next step without the connector name when the [ENT] key is pushed twice without inputting the character. Input the wire arrangement side (right side) to the circuit number on the input side. An empty circuit inputs only the [ENT] key. No. Display > Input value Input > [ 1 ] 1 and [ENT] > [ ] [ENT] > [ 2 ] 2 and [ENT] > [ 3 ] 3 and [ENT] > [ 4 ] 4 and [ENT] > [ 5 ] 5 and [ENT] > [ 7 ] 7 and [ENT] Data registration Register the input wire arrangement data pushing the [INP] key at the end. Note If this operation is not done, the created data is not registered. Key switch Switch the mode change switch to the [WORK] side. Note After the existing pattern is cleared once, a new pattern is registered in an existing pattern when overwriting.

37 Page Example of Inputting Master (Opening) Wire Arrangement [Example of Pattern] [Master wire arrangement side] This side is input. The pattern input and the registration procedure of the above-mentioned conduction wire arrangement is shown. <Input example> Pattern number: 21, Connector name: 20P-Open Key switch Switch the mode change switch to the [MEMORY] side. Mode selection Push the [INP] key. Input mode Input 1, and the pattern input is specified. Pattern number Input 21, and fix the pattern number 21 with the [ENT] key. Number of wire arrangement side total pins Input 20, and fix the number 20 of wire arrangement side total pins with the [ENT] key. Number of input side total pins Input 20, and fix the number 20 of input side total pins with the [ENT] key. * Same number of total pins as the wire arrangement side is input at the one side opening.

38 Page 31 Connector name Data of connecting wires Input 2 and push [ENT] key, and, and input n and push [ENT] twice, and the connector name of 20P-Open is fixed. * The character input is fixed with the [ENT] key while looking for one character pushing the [+/-] key. * It proceeds to the next step without the connector name when the [ENT] key is pushed twice without inputting the character. The wire arranged circuit inputs the same number as the display. An empty circuit inputs only the [ENT] key. No. Display > Input value Input > [ 1 ] 1 and [ENT] > [ 2 ] 2 and [ENT] > [ 3 ] 3 and [ENT] > [ 4 ] 4 and [ENT] > [0 0 0 ] [ENT] > [ 6 ] 6 and [ENT] > [ 7 ] 7 and [ENT] Data registration Register the input wire arrangement data pushing the [INP] key at the end. Note If this operation is not done, the created data is not registered. Key switch Switch the mode change switch to the [WORK] side. Note After the existing pattern is cleared once, a new pattern is registered in an existing pattern when overwriting.

39 Page Confirmation of Wire Arrangement Data It explains the procedure for confirming the wire arrangement data of pattern No.10. Key switch Switch the mode change switch to the [MEMORY] side. Mode selection Press the [CHK] key, and the memory check is specified. Pattern number Input 10, and fix the pattern number 10 with the [ENT] key. Wire arrangement data confirmation Parameter confirmation End Confirm the wire arrangement data pushing the [+/-] key. It advances toward the opposite direction when the [SFT] key is pushed on the way. When the [ENT] key is pushed in the above state, it switches to the parameter display. Confirm the parameter pushing the [+/-] key. * It returns to the wire arrangement data display when the [ENT] key is pushed again. It returns to the memory mode menu screen when the [CLR] key is pushed. Key switch Switch the mode change switch to the [WORK] side.

40 Page Maintenance and Check 8.1. Daily Maintenance 1) Maintenance of machine Before a work start, please carry out the machine check in accordance with the startup checklist in this manual, and start work after checking that it satisfies a standard. * Please record each check result simultaneously. 2) Removal of foreign article Foreign article may creep into a pusher, a wire guide comb, an upper cover setting part and a table sliding part during the operation. Remove these foreign articles from time to time. * If neglect the foreign article, it may results in the cause of wiring defect. 3) Cleaning of work end Please wipe with a dry cloth lightly after cleaning a machine with compression air every day at the time of a work end. There is an effect that maintains a sensor function and prevents rusting. 4) Lubrication Apply a proper amount of Lithium family grease (JIS No. 2) or equivalent to the table sliding part and the pusher sliding part with the frequency of once a month.

41 Page Check of Machine Please confirm the standard value with the corresponding connector termination specifications of the latest version before the operation. 1) Wire protruding length The wire protruding length from the upper cover must be a standard value or less. <Standard>Wire protruding length = 0.3mm or less 2) Shear drop of conductor The conductor shear-drop amount of the cut wire must be a standard value or less, and it must not be short-circuited between pitches. <Standard> Conductor shear-drop amount = Do not exceed the outside diameter of the insulation of the wire. 3) Wire press-fit depth The wire must be press-fitted to the upper cover surely without extremely crushing the wire insulation. 4) Crack on wire insulation A remarkable crack by the wire guide comb and the pusher, etc. do not be on the wire insulation. 5) Damage of upper cover There must be neither damages nor remarkable cracks of the upper cover by the pusher. Damage of upper cover Shear-drop of conductor Crack of wire insulation Wire protruding length Crack of wire insulation

42 Page Exchange Method of Pushers (Wire press-fitting blade) 1) Turn off the power on/off switch, and remove the upper cover of the main body. 2) Set an upper cover (1) to the table (2). 3) Remove the right and left insertion guide (3) in assembly. 4) Exchange the pusher (4) for a spear pusher, and fix it temporarily. 5) Make the position in which the point of the pusher enters the ditch of the upper cover while rotating an eccentric cam (5) by 180 degrees. 6) Place the upper cover (1) with a right and left pusher (4), and fix the pusher in the state. 7) Confirm that the pusher is vertically fixed and moves vertically up and down at this time. 8) Turn the eccentric cam (5), and return the pusher to the former position. 9) Set the right and left insertion guide (3), and fix it while pressing it backward. 10) After confirming the excellence by trial, set the upper cover of the main body. Sensor Insertion guide (3) Pusher (4) Eccentric cam (5) Table (2) Upper cover (1)

43 Page Adjustment Method of Original Position The original position of the table is adjusted so that the pusher may descend to the center of the upper cover ditch. (Unit of adjustment: 0.1mm or 0.127mm) 1) Switch to the [WORK] side after switching the mode change switch to the [MEMORY] side. 2) Push the [SFT] key on the wire arrangement mode main screen, and the keyword input screen opens. 3) Input 999, and the original point adjustment screen is opened pushing the [ENT] key. * It is a meaning that adjusts the place that moved from the set position (worker side) to 400 pulse machine side to the original position when displayed as pulse = ) The table is moved to the original position pushing the [SET/START] switch twice. 5) Detach the right and left insertion guide in assembly, and it puts into the state to see the upper cover and the pusher. 6) Depress the pusher lightly with a hex-head wrench etc, and confirm whether the pusher almost descends to the center of the upper cover ditch. 7) The table moves by one pulse when the [+/-] key is pushed for the necessity the adjustment of the position. The direction that moves with the [SFT] key is switched. (Pulse + N) = It moves in the machine. (Pulse - N) = It moves to the operator side. <Wire arrangement mode main screen> P t n N o P 2 0 P P i n N o. [ ] <Keyword input> K e y w o r d N o. I n p u t! N o = [ ] <Original position adjustment> * A d j u s t t h e o r i g i n * P u l s e = [ ] <Original position adjusted to + side> * A d j u s t t h e o r i g i n * P u l s e = [ ] <Original position adjusted to - side> * A d j u s t t h e o r i g i n * P u l s e = [ ] <Wire arrangement mode main screen> P t n N o P 2 0 P P i n N o. [ ] Pusher (1) 8) When the adjustment of the position ends, fix it with the [ENT] key. Upper cover (2) 9) The right and left insertion guide is installed at the end. Table (3)

44 Page Exchange Method of Switches There is a necessity for detaching a front panel when switch each place is exchanged. Please do this exchange according to the procedure below order. 1) Detach the connector of the switch that wants to be exchanged from the PCB. 2) Detach the screw in three places under a front panel, and remove the front panel from the main body while noting other wiring. 3) Detach the exchanged switch from the front panel. * Remove the switch gradually while pushing the hook that hangs in the switch. 4) Insert a new connector (The harness has been processed) from the surface of a front panel. * The hook hangs when the switch is pushed. 5) Connect the connector of the switch with the prescribed position of the main PCB. Front panel Switch Connect the connector with the main PCB.

45 Page Exchange Method of Ten-key Ten-key is fixed to the front panel with the double-faced tape, and detaching is easy. 1) Detach the main body cover. 2) Remove the flat cable of the ten-key from the KEY PCB under the LCD. 3) Remove the obituary part in the ten-key seat forcibly from the front panel. 4) Insert the flat cable of new ten-key from the front panel, and fix the ten-key to the front panel with the double-faced tape. 5) Connect the flat cable with the KEY PCB. * Insert the flat cable up to the interior noting so that it should not bend. To KEY PCB under LCD Flat cable Ten-key

46 Page Version of Software The version of software can be confirmed according to the following procedure. 1) Switch to the [WORK] side after switching the mode change switch to the [MEMORY] side. 2) Push the [SFT] key on the wire arrangement mode main screen, and then the key word input screen opens. 3) Input 888 and fix it with the [ENT] key, and then the version of software is displayed. 4) The software version 1.00 of 1.27mm pitch machine is shown in the example of the right. 5) It returns to the main screen when the [ENT] key or the [CLR] key is pushed after it displays the version. <Wire arrangement mode main screen> P t n N o P 2 0 P P i n N o. [ ] <Keyword input> K e y w o r d N o. I n p u t! N o. [ ] <Input 888 > K e y w o r d N o. I n p u t! N o. [ ] <Version of Software> S e l e c t o r V e r s i o n